Diffusion sheet, rear projection screen provided with diffusion sheet, method of manufacturing mold for diffusion sheet, and method of manufacturing diffusion sheet

ABSTRACT

In a diffusion sheet, a plurality of approximately trapezoidal columnar unit lens portions are disposed such that the long-axis directions thereof are in parallel with each other, and all the surfaces of the unit lens portions, which correspond to the long bottom segments of the approximately trapezoidal sections of the unit lens portions are disposed on a light-incident-side flat surface. Further, light absorbing portions are disposed in the grooves between adjacent unit lens portions to absorb and/or shield external light incident from a light outgoing side. In the diffusion sheet arranged as described above, light incident on the unit lens portions from a light incident side is totally reflected on the surfaces corresponding to the side segments of the approximately trapezoidal sections vertical to the long-axis direction of the unit lens portions and outgoes from the light outgoing side.

This is a Divisional of application Ser. No. 10/518,305 filed Dec. 17,2004 now U.S. Pat. No. 7,453,639, which is a National Phase ofApplication No. PCT/JP2004/004202 filed Mar. 25, 2004, which claims thebenefit of Japanese Patent Application No. 2003-82693 filed Mar. 25,2003 and Japanese Patent Application No. 2003-119588 filed Apr. 24,2003. The disclosures of the prior applications are hereby incorporatedby reference herein in their entirety.

TECHNICAL FIELD

The present invention relates to a diffusion sheet assembled in a rearprojection screen (transmission type screen) and used therein, and moreparticularly, to a diffusion sheet in which a plurality of approximatelytrapezoidal columnar unit lens portions (unit optical elements) aredisposed, a rear projection screen provided with the diffusion sheet, amethod of manufacturing a mold for a diffusion sheet, and a method ofmanufacturing a diffusion sheet.

BACKGROUND ART

Heretofore, there is known an image display apparatus having a lightsource and a rear projection screen that projects image light emittedfrom the light source in enlargement, as a typical image displayapparatus represented by a rear projection type television. Further,there is generally known a rear projection screen composed of a Fresnellens sheet combined with a lenticular lens sheet (diffusion sheet) asthe rear projection screen used in the image display apparatus.

The Fresnel lens sheet adjusts image light emitted from a light sourceto make it to approximate parallel light. There is also a Fresnel lenssheet which collects or diverges light from a light source to a lightoutgoing side, in addition to the Fresnel lens sheet that adjusts lightfrom the light source to make it to parallel light. In the description,however, explanation is made supposing that light emitted from a Fresnellens sheet is approximately parallel light.

The lenticular lens sheet causes approximately parallel light adjustedby the Fresnel lens sheet to outgo to an observer as diverged light sothat the observer can observe an image on a rear projection screen atvarious angular positions. More specifically, the lenticular lens sheetdiffuses the approximately parallel light outgoing from the Fresnel lenssheet mainly in a horizontal direction as well as also in a verticaldirection.

Incidentally, there is known a lenticular lens sheet having a pluralityof unit lens portions each having a total reflection surface formed on apart of a side thereof, as the lenticular lens sheet described above.Note that light absorbing portions are formed between the unit lensportions as necessary to prevent the reflection of external light.

More specifically, there is known a lenticular lens sheet having aplurality of unit lens portions disposed thereto, as a first lenticularlens sheet, each of the unit lens portions having a curved surfaceformed on a light outgoing side vertex and total reflection surfacesformed to a part of side surfaces (refer to Japanese Patent ApplicationLaid-Open Nos. 57-165830, 62-108232, and 60-159733).

Further, there is known a lenticular lens sheet having a plurality ofunit lens portions disposed thereto, as a second lenticular lens sheet,each of the unit lens portions having a curved surface formed on a lightoutgoing side vertex as well as total reflection surfaces formed to apart of side surfaces, and at least two types of unit lens portions,each of which has a different tilt angle of the total reflection surfaceand a different lens height, being combined as one unit (refer toJapanese Patent Application Laid-Open Nos. 59-140434 and 59-68726).

However, since each unit lens portion of the first and second lenticularlens sheets described above has the curved surface formed on the lightoutgoing side vertex, a problem arises in that a support sheet cannot bejoined to the unit lens portions to support them. Further, a problemalso arises in that a lens is liable to be scratched and made dirtybecause a light outgoing surface of the lenticular lens sheet is formedin an irregular shape due to the curved surfaces of the unit lensportions, and thus the surface thereof cannot be wiped by hand.

Further, since a light absorbing portion cannot be formed to absorb andshield external light in the second lenticular lens sheet describedabove, the second lenticular lens sheet is disadvantageous in that whenan observer views a display, it is difficult for an observer to observean image because a contrast is low in a bright portion and a darkportion. Further, the second lenticular lens sheet is alsodisadvantageous in that it is difficult to enhance the resolution of animage by miniaturizing a lenticular lens because the second lenticularlens sheet is formed in a complex shape.

To cope with the above problems, heretofore proposed is a lenticularlens sheet having a plurality of unit lens portions disposed in parallelwith each other, each of the unit lens portions having total reflectionsurfaces formed on the side surfaces of each approximately trapezoidalcolumn, as a third lenticular lens sheet (refer to Japanese PatentApplication Laid-Open Publication No. 2002-006112). However, the thirdlenticular lens sheet has the following problems, which will beexplained below in detail.

As shown in FIG. 18A, light, which is emitted from a light source (notshown) and adjusted by a Fresnel lens sheet (not shown) so that it ismade to approximately parallel light, is incident on a lenticular lenssheet 700. A part of the light, which is incident on the lenticular lenssheet 700 as described above, travels linearly through the lenticularlens sheet 700 and outgoes therefrom (L2′). However, the other light isreflected on one side of a trapezoidal columnar unit lens portion,refracted on a light outgoing side thereof, and outgoes therefrom (L1′).On the other hand, the other light is also reflected on the other sideof the trapezoidal columnar unit lens portion, refracted on the lightoutgoing side thereof, and outgoes therefrom (L3′). As described above,the light outgoing from trapezoidal columnar unit lens portions disposedto the lenticular lens sheet 700 forms the three groups of light (L1′,L2′, L3′). Accordingly, when the brightness (gain) of an image formed bythe light outgoing from the lenticular lens sheet 700 is measured withrespect to a horizontal observation angle, there is obtained a gaincurve which has a steep slope with three peaks corresponding to thegroups of light (refer to FIG. 18B).

When an observer views an image displayed on a rear projection typetelevision using the lenticular lens sheet 700 arranged as describedabove from the front of the television, the observer views the centralportion of the television with the brightness at the position of 0° inthe gain curve. In contrast, the observer views both the right and leftends of the television with the brightness at the positions of ±7.6° inthe gain curve when both the ends are viewed at the position five timesthe height of a screen apart from the television, supposing that thetelevision is a mass-produced television having a screen whose aspectratio is set to 3:4, although the brightness is different depending onthe distance of a position apart from the television where the image isviewed. Accordingly, in the lenticular lens sheet having a distributionof brightness (gain curve) including the steep slope with the threepeaks, the observer views an image having bad bright uniformity. When,for example, the observation angles at both the right and left ends ofthe rear projection type television are approximately in agreement withan angle showing a minimum value of the gain curve, the differencebetween the brightness in the central portion of the television and thebrightness at both the ends thereof extremely increases, thereby theobserver views an image having extremely bad bright uniformity.

Further, when the observer views an image on the rear projection typetelevision using the lenticular lens sheet 700 while moving in ahorizontal direction from one end of the television to the other endthereof, the observer views the image, which extremely changes in thesequence of “dark, bright, dark, bright, dark, bright, dark” in thecentral portion of an image surface of the television. At the time, aproblem arises in that an image having good bright uniformity cannot beviewed because the bad bright uniformity described above is also added.

Note that when the third lenticular lens sheet as described above isactually manufactured, a metal mold (mold) is used in consideration ofmass production. Ordinarily, the metal mold is manufactured bysequentially forming trapezoidal columnar recesses (grooves)corresponding to unit lens portions on a mold material such as a metalsubstrate and the like by cutting it from an end thereof.

However, when the metal material is cut by the above method, a metalmold 705 is manufactured in such a shape that projections formed betweenadjacent recesses tilt from the sides of subsequently cut recessestoward the sides of previously cut recesses, as shown in FIG. 19A. Whena lenticular lens sheet is manufactured using the metal mold 705arranged as described above, a side segment, where the recess is formedpreviously, of the section of each trapezoidal columnar unit lensportion draws a curved line projecting inward, and the other sidesegment of the section draws a curved line projecting outward as shownin n FIG. 19B. Explained above is the example arranged such that theprojections, which are made by forming the recesses for the unit lensportions by cutting the metal material, are deformed (plasticallydeformed) outward when viewed from the recesses being processed (FIG.19A). However, there is also a case that a metal mold is manufactured soas to have such as a shape that projections formed to a metal materialare deformed (elastically deformed) inward when viewed from recessesbeing processed, and projections formed between adjacent recesses tiltfrom the sides of recesses formed previously toward the sides ofrecesses formed subsequently, adversely to the above case. Note that alenticular lens sheet 701 having the same shape as that shown in FIG.19B can be manufactured even by the metal mold manufactured in thelatter case.

Note that, when the lenticular lens sheet 701 manufactured as describedabove is used, a part of light incident thereon after it is adjusted andmade to parallel light travels linearly and outgoes therefrom (L1″) asshown in FIG. 19B. Further, when the light, which is incident on thelenticular lens sheet 701 as described above, is reflected on theoutwardly curved side surface of each trapezoidal columnar unit lensportion, it outgoes mainly at an angle near to a center (L2″), and whenthe light is reflected on the inwardly projecting side surface, itoutgoes mainly at an angle apart from the center (L3″). As a result, again curve of the lenticular lens sheet 701, which shows the brightness(gain) of an image to a horizontal observation angle, is a right/leftasymmetrical curve as shown in FIG. 19C. Note that the terms “right” and“left” used here correspond to “right” and “left” when the lenticularlens sheet 701 is assembled and used in the rear projection screen forthe rear projection type television.

When the observer views an image between, for example, the lightoutgoing angles L1″ and L3″ in the rear projection type television usingthe lenticular lens sheet 701, he or she views the image in a darkstate. Accordingly, when the observer views the image while moving in ahorizontal direction from one end side to the other end side of the rearprojection type television using the lenticular lens sheet 701 (whilemoving from the right side to the left side of FIG. 19B), the image isviewed in the sequence of “dark, bright, dark, bright, dark, bright” atthe center of a screen, from which a problem arises in that it isdifficult to view the image because irregular brightness is caused inthe image. Further, when the observer views the image displayed on therear projection type television using the lenticular lens sheet 701 fromthe front, a problem arises in that he or she views the image having abad right/left balance, that is, bad bright uniformity.

DISCLOSURE OF THE INVENTION

An object of the present invention, which has been made in view of theabove points, is to provide a diffusion sheet used by being assembled ina rear projection screen of a rear projection type television, a rearprojection screen provided with the diffusion sheet, a method ofmanufacturing a mold for a diffusion sheet, and a method ofmanufacturing the diffusion sheet, the diffusion sheet being capable ofpresenting an image which has good bright uniformity in an image surfacewhen it is viewed from the front, and further which has less variablebrightness as well as good bright uniformity and good distribution ofbrightness in the image surface even if an observer views the imagewhile moving in a horizontal direction.

The present invention provides, as a first solving means, a diffusionsheet that diffuses light incident thereon from a light incident sideand causes the light to outgo from a light outgoing side, the diffusionsheet including: a plurality of approximately trapezoidal columnar unitlens portions disposed such that the long-axis directions thereof are inparallel with each other, wherein all the surfaces of the unit lensportions, which correspond to the long bottom segments of theapproximately trapezoidal sections of the unit lens portions vertical tothe long-axis directions thereof, are disposed on a light-incident-sideflat surface; and a plurality of light absorbing portions interposedbetween adjacent unit lens portions of the plurality of unit lensportions to absorb external light incident from the light outgoing side,wherein the plurality of unit lens portions are arranged such that apart of the light incident on the unit lens portions from the lightincident side is totally reflected on the surfaces of the unit lensportions corresponding to the side segments of the approximatelytrapezoidal sections of the unit lens portions vertical to the long-axisdirections thereof, and the distance between the long bottom segment andthe short bottom segment of the approximately trapezoidal section ofeach of the unit lens portions vertical to the long-axis directionthereof is 120% or more to 400% or less of the length of the long bottomsegment.

According to the first solving means of the present invention, thedistance between the long bottom segment and the short bottom segment ofthe approximately trapezoidal section of each of the unit lens portionsvertical to the long-axis direction thereof is 120% or more to 400% orless of the length of the long bottom segment. Accordingly, the outgoingdirection of the light, which is reflected on the side surfaces(surfaces corresponding to the side segments of the approximatelytrapezoidal section) acting as the total reflection surfaces, deflectsin the direction of light which travels straight in the unit lensportions. As a result, when the gain obtained by the diffusion sheet ismeasured, a gain curve, which shows brightness (gain) to a viewing anglein a horizontal direction (angle between a viewing direction and thenormal direction of the sheet), is a curve which is gentle in itsentirety with one peak at a center. Since the diffusion sheet has theabove gain curve, when a observer views an image on a rear projectionscreen, and the like provided with the diffusion sheet from the front ofthe diffusion sheet, the image has good bright uniformity in an imagesurface. Further, even if the observer views the image while moving in ahorizontal direction, the brightness of a particular part in the imagesurface does not extremely change and an image excellent brightuniformity can be obtained. Specifically, the observer views the imagefrom the front of the sheet surface, he or she views the brightestimage, and the observer views the image becoming gradually darker as heor she moves in the horizontal direction from the point where he or sheviews the image because the angle between a vertical line to the sheetsurface and the line of vision of the observer is increased thereby.However, since the image becomes darker gradually at the time, theobserver can easily view the image in a natural state. Further, even ifthe observer views the image at rest at a position other than the front(however, a position within a viewing angle at which the image can bepreferably viewed), the observer can easily view the image in thenatural state because no irregular brightness exists in one imagesurface and he or she can view the image excellent in bright uniformity.

The present invention provides, as a second solving means, a diffusionsheet that diffuses light incident thereon from a light incident sideand causes the light to outgo from a light outgoing side, the diffusionsheet including: a plurality of approximately trapezoidal columnar unitlens portions disposed such that the long-axis directions thereof are inparallel with each other, wherein all the surfaces of the unit lensportions, which correspond to the long bottom segments of theapproximately trapezoidal sections of the unit lens portions vertical tothe long-axis directions thereof, are disposed on a light-incident-sideflat surface; and a plurality of light absorbing portions interposedbetween adjacent unit lens portions of the plurality of unit lensportions to absorb external light incident from the light outgoing side,wherein the plurality of unit lens portions are arranged such that apart of the light incident on the unit lens portions from the lightincident side is totally reflected on the surfaces of the unit lensportions corresponding to the side segments of the approximatelytrapezoidal sections vertical to the long-axis directions of the unitlens portions, and the section of each of the unit lens portionsvertical to the long-axis direction thereof is formed in an isoscelestrapezoidal shape, and the plurality of unit lens portions have at leasttwo types of unit lens portions each having a different angle betweeneach side segment and the light-incident-side long bottom segment of theisosceles trapezoidal section.

According to the second solving means of the present invention, thesection of each of the unit lens portions vertical to the long-axisdirection thereof is formed in the isosceles trapezoidal shape, and thediffusion sheet includes at least the two types of the unit lensportions, the isosceles trapezoidal section of each of which has thedifferent angle between each side segment and the light-incident-sidelong bottom segment thereof. Accordingly, light, which is reflected onthe side surfaces acting as the total reflection surfaces (surfacescorresponding to the side segments of the approximately trapezoidalsection), outgoes in at least four directions and outgoes in at leastfive directions in total when light, which travels straight and passesthrough the diffusion sheet as it is, is taken into consideration. As aresult, when the gain obtained by the diffusion sheet is measured, again curve, which shows brightness (gain) to a viewing angle in ahorizontal direction (angle between a viewing direction and the normaldirection of the sheet), has at least five peaks (maximum values) ofbrightness corresponding to the respective light outgoing directions.Since the bottoms of the peaks overlap, the gain curve is a right/leftsymmetrical gentle curve having a peak at a center in its entirety.Since the diffusion sheet has the gain curve as described above, whenthe observer views an image in the front, there is no part in which theimage is viewed extremely dark. Further, since the diffusion sheetarranged as described above has a plurality of light outgoing angles, itis possible to increase a viewing angle on the side where the image isviewed. Accordingly, when the observer views the image from the front ofa rear projection screen provided with the diffusion sheet, he or shecan view the image which is symmetrical on the right side and the leftside and has a good distribution of brightness. Further, even if theobserver views the image while moving in a horizontal direction, he orshe can view the image which less varies in brightness and is excellentin bright uniformity. Further, even if the observer views the image atrest at a position other than the position from the front of the rearprojection screen (however, a position within a viewing angle at whichthe image can be preferably viewed), he or she can view the imageexcellent in the bright uniformity.

The present invention provides, as a third solving means, a diffusionsheet that diffuses light incident thereon from a light incident sideand causes the light to outgo from a light outgoing side, the diffusionsheet including: a plurality of approximately trapezoidal columnar unitlens portions disposed such that the long-axis directions thereof are inparallel with each other, wherein all the surfaces of the unit lensportions, which correspond to the long bottom segments of theapproximately trapezoidal sections of the unit lens portions vertical tothe long-axis directions thereof, are disposed on a light-incident-sideflat surface; and a plurality of light absorbing portions interposedbetween adjacent unit lens portions of the plurality of unit lensportions to absorb external light incident from the light outgoing side,wherein the plurality of unit lens portions are arranged such that apart of the light incident on the unit lens portions from the lightincident side is totally reflected on the surfaces of the unit lensportions corresponding to the side segments of the approximatelytrapezoidal sections vertical to the long-axis directions of the unitlens portions, and the approximately trapezoidal section of each of theunit lens portions vertical to the long-axis direction thereof has afirst angle between one side segment and a light-incident-side longbottom segment, and a second angle between the other side segment andthe light-incident-side long bottom segment, the first angle beingdifferent from the second angle.

According to the third solving means of the present invention, the firstangle between one side segment and the light-incident-side long bottomsegment of the approximately trapezoidal section of each of the unitlens portions vertical to the long-axis direction thereof is differentfrom the second angle between the other side segment and thelight-incident-side long bottom segment of the section. Accordingly,when the diffusion sheet is arranged such that the bottom angles (anglesbetween the side segments and the long bottom segment) of the parts ofadjacent unit lens portions at which they are in contact with each otherhave the same angle, light, which is reflected on the side surfacesacting as the total reflection surfaces (surfaces corresponding to theside segments of the approximately trapezoidal section), outgoes in atleast four directions and outgoes in at least five directions in totalwhen light, which travels straight and passes through the diffusionsheet as it is, is taken into consideration. As a result, when the gainobtained by the diffusion sheet is measured, a gain curve, which showsbrightness (gain) to a viewing angle in a horizontal direction (anglebetween a viewing direction and the normal direction of the sheet), hasat least five peaks of brightness corresponding to the respective lightoutgoing directions. Since the bottoms of the peaks overlap, the gaincurve is a gentle curve which is symmetrical on the right side and theleft side and has a peak at a center in its entirety. Since thediffusion sheet has the gain curve as described above, when the observerviews an image in the front, the image is not viewed in an extremelydark state. Further, since the diffusion sheet arranged as describedabove has a plurality of light outgoing angles, it is possible toincrease a viewing angle on the side where the image is viewed.Accordingly, when the observer views the image from the front of a rearprojection screen provided with the diffusion sheet, he or she can viewthe image which is symmetrical on the right side and the left side andhas a good distribution of brightness. Further, even if the observerviews the image while moving in a horizontal direction, he or she canview the image which less varies in brightness and is excellent in thebright uniformity. Further, even if the observer views the image at restat a position other than the position from the front of the rearprojection screen (however, a position within a viewing angle at whichthe image can be preferably viewed), he or she can view the imageexcellent in the bright uniformity. Furthermore, when the diffusionsheet is arranged as described above, it is possible to simplify theshape of a cutting tool for cutting a mold (metal mold) for thediffusion sheet, thereby a process of manufacturing the cutting tool canbe easily arranged.

Note that, in the first to third solving means described above, it ispreferable that the length of the light-outgoing-side bottom segment ofthe section of each of the light absorbing portions vertical to thelong-axis direction thereof be 40% or more to 100% or less of the lengthof the light-incident-side long bottom segment of the section of each ofthe unit lens portions vertical to the long-axis direction thereof. Withthis arrangement, since the ratio of the light absorbing portionsinterposed between the unit lens portions is increased, the contrast ofan image can be enhanced, thereby the observer can easily view an image.

Further, in the first to third solving means described above, it ispreferable that the section of each of the light absorbing portionsvertical to the long-axis direction thereof interposed between adjacentunit lens portions of the plurality of unit lens portions be formed inan approximately triangular shape, and the vertex of the section on thelight incident side thereof be composed of a straight line segmenthaving a width of at least 2 μm. In this case, the extreme ends of theprojections of the mold which molds a group of the unit lens portions ofthe diffusion sheets, need not be made steep. Accordingly, the strengthof the projections of the mold can be enhanced, thereby the projectionsof the mold can be prevented from being tilted right and left.

Further, in the first to third solving means described above, it ispreferable that the section of each of the light absorbing portionsvertical to the long-axis direction thereof interposed between adjacentunit lens portions of the plurality of unit lens portions be formed inan approximately triangular shape, and the vertex of the section on thelight incident side thereof be composed of a curved line segment havinga radius of curvature of at least 1 μm. In this case, the extreme endsof the projections of the mold which molds a group of the unit lensportions of the diffusion sheets, also need not be made steep.Accordingly, the strength of the projections of the mold for a diffusionsheet can be enhanced, thereby the projections of the mold can beprevented from being tilted right and left.

Further, in the first to third solving means described above, it ispreferable that the diffusion sheet further includes a support platedisposed on the light outgoing side of the unit lens portions andcontaining a diffusion agent. With this arrangement, it is possible toform a layer having other function on the support plate. Further, lightoutgoing from the unit lens portions and traveling in one direction isdiffused by the diffusion agent and can travel in a plurality ofdirections, thereby the irregular brightness of an image, which changesdepending on a position of the observer, can be reduced. Note that, inthis case, the peaks (maximum values) of the gain curve described aboveother than the peak at the center thereof can be eliminated.

Further, in the first to third solving means described above, it ispreferable that the light outgoing side surface of the support plate beformed flat. With this arrangement, an image can be displayed on a flatsurface, thereby the observer can easily view the image. Further, sincethe surface of the diffusion sheet is not curved and has noirregularities, the surface can be simply wiped by hand, thereby it ispossible to make the surface of the diffusion sheet free from scratchesand dusts.

Further, in the first to third solving means described above, it ispreferable that the support plate has an ultraviolet ray absorbingaction. With this arrangement, ultraviolet rays included in externallight can be absorbed by the support plate, thereby a plastic materialconstituting the unit lens portions, and the like in the diffusion sheetcan be prevented from being deteriorated (color change, qualitydeterioration, and the like).

Further, in the first to third solving means described above, it ispreferable that the unit lens portions be composed of a radiationsetting resin. With this arrangement, it is possible to obtain adiffusion sheet having unit lens portions molded faithfully to a moldshape.

The present invention provides, as a fourth solving means, a rearprojection screen including: the diffusion sheet according to the firstto third solving means described above; and a Fresnel lens sheetdisposed on the light incident side of the diffusion sheet.

According to the fourth solving means of the present invention, the rearprojection screen is composed of the diffusion sheet according to thefirst to third solving means described above and the Fresnel lens sheetdisposed on the light incident side of the diffusion sheet. Accordingly,there can be provided a display on which the observer can view an imageeasily, the display having no irregular brightness in an image surfaceand having good bright uniformity therein even if the observer views theimage while moving in a horizontal direction or even if the observerviews the image at rest at a position from the front of the display orat a position other than the above position (however, a position withina viewing angle at which the image can be preferably viewed).

The present invention provides, as a fifth solving means, a diffusionsheet that diffuses light incident thereon from a light incident sideand causes the light to outgo from a light outgoing side, the diffusionsheet including: a plurality of approximately trapezoidal columnar unitlens portions disposed such that the long-axis directions thereof are inparallel with each other, wherein all the surfaces of the unit lensportions, which correspond to the long bottom segments of theapproximately trapezoidal sections of the unit lens portions vertical tothe long-axis directions thereof, are disposed on a light-incident-sideflat surface; and a plurality of light absorbing portions interposedbetween adjacent unit lens portions of the plurality of unit lensportions to absorb external light incident from the light outgoing side,wherein the plurality of unit lens portions are arranged such that apart of the light incident on the unit lens portions from the lightincident side is totally reflected on the surfaces of the unit lensportions corresponding to the side segments of the approximatelytrapezoidal sections vertical to the long-axis directions of the unitlens portions, and at least one side segment of the approximatelytrapezoidal section of each of the unit lens portions vertical to thelong-axis direction thereof is composed of a curved line segmentprojecting inward or a curved line segment projecting outward, and theplurality of side segments of the sections of the plurality of unit lensportions include, as a whole, both the side segments each composed ofthe curved line segment projecting inward and the side segments eachcomposed of the curved line segment projecting outward.

According to the fifth solving means of the present invention, at leastone side segment of the approximately trapezoidal section of each of theunit lens portions vertical to the long-axis direction thereof iscomposed of the curved line segment projecting inward or the curved linesegment projecting outward, and the plurality of side segments of thesections of the plurality of unit lens portions include, as a whole,both the side segments each composed of the curved line segmentprojecting inward and the side segments each composed of the curved linesegment projecting outward. Accordingly, light incident from a lightsource outgoes after it is reflected on the total reflection surfaceshaving various angles (surfaces corresponding to the respective sidesegments of the approximately trapezoidal sections). As a result, whenthe gain obtained by the diffusion sheet is measured, a gain curve,which shows brightness (gain) to a viewing angle in a horizontaldirection (angle between a viewing direction and the normal direction ofthe sheet), is a gentle curve having one peak at a center and expandingin the range of a wide angle in its entirety. Accordingly, when theobserver views an image from the front of a rear projection screenprovided with the diffusion sheet, he or she can view the imageexcellent in bright uniformity. Further, even if the observer views theimage while moving in a horizontal direction, he or she can view theimage which less varies in brightness and is excellent in the brightuniformity. Further, even if the observer views the image at rest at aposition other than the position from the front of the rear projectionscreen (however, a position within a viewing angle at which the imagecan be preferably viewed), he or she can view the image excellent in thebright uniformity.

In the fifth solving means described above, it is preferable that: thenumber of the side segments, which are composed of the curved linesegments projecting inward, of the sections of the unit lens portions beapproximately the same as the number of the side segments, which arecomposed of the curved line segments projecting outward, of the sectionsof the unit lens portions in the diffusion sheet as a whole; the numberof the unit lens portions whose right side segments are composed of thecurved line segments projecting inward be approximately the same as thenumber of the unit lens portions whose left side segments are composedof the curved line segments projecting inward in the diffusion sheet asa whole; and the number of the unit lens portions whose right sidesegments are composed of the curved line segments projecting outward beapproximately the same as the number of the unit lens portions whoseleft side segments are composed of the curved line segments projectingoutward in the diffusion sheet as a whole. Specifically, it ispreferable, for example, that the number of the unit lens portions,which have the side segments composed of the curved line segmentsprojecting inward on the right and left sides, be approximately the sameas the number of the unit lens portions, which have the side segmentscomposed of the curved line segments projecting outward on the right andleft sides, in the state that the unit lens portions are used. In thiscase, when the vertical axis of the gain curve showing brightness (gain)with reference to a horizontal viewing direction shows a gain and thelateral line thereof shows a viewing angle (angle between a viewingdirection and the normal direction of the sheet), the gain curve issymmetrical on the right side and the left side about a point of originof the lateral line. Accordingly, there can be viewed an image which hasa good balance on the right side and the left side in an image surfaceand good bright uniformity.

Further, in the fifth solving means described above, it is preferablethat the unit lens portions each having the section whose side segmentsare both composed of the curved line segment projecting inward, and theunit lens portions each having the section whose side segments are bothcomposed of the curved line segment projecting outward be disposedalternately.

Further, in the fifth solving means described above, one side segment ofthe approximately trapezoidal section of each of the unit lens portionsvertical to the long-axis direction thereof may be composed of a curvedline segment, and the other side segment thereof may be composed of astraight line segment. In this case, it is preferable that: the numberof the side segments, which are composed of the curved line segmentsprojecting inward, of the sections of the unit lens portions beapproximately the same as number of the side segments, which arecomposed of the curved line segments projecting outward, of the sectionsof the unit lens portions in the diffusion sheet as a whole; the numberof the unit lens portions whose right side segments are composed of thecurved line segments projecting inward be approximately the same as thenumber of the unit lens portions whose left side segments are composedof the curved line segments projecting inward in the diffusion sheet asa whole; the number of the unit lens portions whose right side segmentsare composed of the curved line segments projecting outward beapproximately the same as the number of the unit lens portions whoseleft side segments are composed of the curved line segments projectingoutward in the diffusion sheet as a whole; and the number of the unitlens portions whose right side segments are composed of the straightline segments be approximately the same as number of the unit lensportions whose left side segments are composed of the straight lines inthe diffusion sheet as a whole.

Further, in the fifth solving means described above, it is preferablethat the diffusion sheet further includes a support plate disposed onthe light outgoing side of the unit lens portions and containing adiffusion agent. With this arrangement, it is possible to form a layerhaving other function on the support plate. Further, light outgoing fromthe unit lens portions and traveling in one direction is diffused by thediffusion agent and can travel in a plurality of directions, thereby theirregular brightness of an image, which changes depending on a positionof the observer, can be reduced. Note that, in this case, the maximumvalues of the gain curve described above other than the peak at thecenter can be eliminated.

Further, in the fifth solving means described above, it is preferablethat the light-outgoing-side surface of the support plate be formedflat. With this arrangement, an image can be displayed on a flatsurface, thereby the observer can easily view the image. Further, sincethe surface of the diffusion sheet is not curved and has noirregularities, the surface can be simply wiped by hand, thereby it ispossible to make the surface of the diffusion sheet free from scratchesand dusts.

Further, in the fifth solving means described above, it is preferablethat the support plate has an ultraviolet ray absorbing action. Withthis arrangement, ultraviolet rays included in external light can beabsorbed by the support plate, thereby a plastic material constitutingthe unit lens portions, and the like in the diffusion sheet can beprevented from being deteriorated (color change, quality deterioration,and the like).

Further, in the fifth solving means described above, it is preferablethat the unit lens portions are composed of a radiation setting resin.With this arrangement, it is possible to obtain a diffusion sheet havingunit lens portions molded faithfully to a mold shape.

The present invention provides, as a sixth solving means, a rearprojection screen including: the diffusion sheet according to the fifthsolving means described above; and a Fresnel lens sheet disposed on thelight incident side of the diffusion sheet.

According to the sixth solving means of the present invention, the rearprojection screen is composed of the diffusion sheet according to thefifth solving means described above and the Fresnel lens sheet disposedon the light incident side of the diffusion sheet. Accordingly, therecan be provided a display on which the observer can view an imageeasily, the display having no irregular brightness in an image surface,having good bright uniformity therein, and having a good distribution ofbrightness symmetrical on the right side and left side even if theobserver views the image while moving in a horizontal direction or evenif the observer views the image at rest at a position from the front ofthe display or at a position other than the above position (however, aposition within a viewing angle at which the image can be preferablyviewed).

The present invention provides, as a seventh solving means, a method ofmanufacturing a mold for a diffusion sheet in which a plurality ofapproximately trapezoidal columnar unit lens portions are disposed suchthat the long-axis directions thereof are in parallel with each other,and all the surfaces of the unit lens portions, which correspond to thelong bottom segments of the approximately trapezoidal sections of theunit lens portions vertical to the long-axis directions thereof, aredisposed on a light-incident-side flat surface, the method including: afirst step of cutting a material of the mold for the diffusion sheet toform a plurality of trapezoidal columnar recesses for unit lens portionswith the material remaining spaces for trapezoidal columnar recesses forone or more adjacent unit lens portions on the material; and a secondstep of cutting the remaining spaces of the material to form thetrapezoidal columnar recesses for the adjacent unit lens portions afterthe completion of the first step.

According to the seventh solving means of the present invention, afterthe material of the mold for the diffusion sheet is cut and a pluralityof trapezoidal columnar recesses for unit lens portions are formedthereto remaining spaces for recesses for one or more adjacent unit lensportions in the material, the remaining spaces of the material are cutand recesses for unit lens portions are formed afterward. Accordingly,the projections located on both the sides or one side of the recessesformed afterward naturally tilt outward thereof (on the sides of therecesses having been formed) or inward thereof. As a result, there canbe manufactured a mold in which the numbers of the projections that tiltright and left are approximately the same as a whole when the mold isused.

The present invention provides, as an eight solving means, a method ofmanufacturing a mold for a diffusion sheet in which a plurality ofapproximately trapezoidal columnar unit lens portions are disposed suchthat the long-axis directions thereof are in parallel with each other,and all the surfaces of the unit lens portions, which correspond to thelong bottom segments of the approximately trapezoidal sections of theunit lens portions, are disposed on a light-incident-side flat surface,the method including: a first step of cutting a material of a mastermold for the diffusion sheet to form a plurality of trapezoidal columnarrecesses for unit lens portions with the material remaining spaces fortrapezoidal columnar recesses for one or more adjacent unit lensportions on the material; a second step of manufacturing the master moldfor the diffusion sheet by cutting the remaining spaces of the materialto form the trapezoidal columnar recesses for the adjacent unit lensportions after the completion of the first step; and a third step ofobtaining the mold for the diffusion sheet by copying the master moldfor the diffusion sheet manufactured at the second step.

According to the eight solving means of the present invention, after thematerial of the master mold for the diffusion sheet is cut and aplurality of trapezoidal columnar recesses for unit lens portions areformed thereto remaining spaces for recesses for one or more adjacentunit lens portions in the material, the remaining spaces of the materialare cut and recesses for unit lens portions are formed afterward.Accordingly, the master mold for the diffusion sheet having the sameshape as that of the mode for the diffusion sheet described above can bemanufactured. Then, there can be manufactured a mold for the diffusionsheet which achieves the same operation/working effect as that of themold for the diffusion sheet according to the seventh solving meansdescribed above by copying the thus manufactured master mold for thediffusion sheet.

The present invention provides, as a ninth solving means, a method ofmanufacturing a diffusion sheet including the steps of: preparing a moldfor the diffusion sheet manufactured by the method according to theseventh solving means described above; coating a liquid resin for unitlens portions in the recesses of the mold for the diffusion sheet sothat it is buried in the recesses; setting the liquid resin buried inthe recesses of the mold for the diffusion sheet; and obtaining thediffusion sheet in which a plurality of approximately trapezoidalcolumnar unit lens portions are disposed, by removing the liquid resinfrom the mold for the diffusion sheet after it is set.

According to the ninth solving means, the diffusion sheet ismanufactured using the mold for the diffusion sheet manufactured by themethod of the seventh solving means described above. Accordingly, therecan be obtained a diffusion sheet including unit lens portions in whichthe number of the side segments, which are composed of curved linesegments projecting inward, of the section of each unit lens portion isapproximately the same as the number of the side segments which arecomposed of curved line segments projecting inward, and the number ofthe curved line segments projecting outward is approximately the same asthe number of the curved line segments projecting outward in terms ofthe right and left side segments. The gain curve of the diffusion sheetobtained as described above is a gentle curve having a peak at a centerand expanding in the range of a wide angle in its entirety. As a result,when the observer views an image from the front of a rear projectionscreen provided with the diffusion sheet, he or she can view the imagewhich has a good right/left balance of brightness and is excellent inbright uniformity. Further, even if the observer views the image whilemoving in a horizontal direction, he or she can view the image whichless varies in brightness and is excellent in the bright uniformity.Further, even if the observer views the image at rest at a positionother than the position from the front of the rear projection screen(however, a position within a viewing angle at which the image can bepreferably viewed), he or she can view the image excellent in the brightuniformity.

The present invention provides, as a tenth solving means, a method ofmanufacturing a diffusion sheet including the steps of: preparing a moldfor the diffusion sheet manufactured by the method according to theeight solving means described above, coating a liquid resin for unitlens portions in the recesses of the mold for the diffusion sheet sothat it is buried in the recesses; setting the liquid resin buried inthe recesses of the mold for the diffusion sheet; and obtaining thediffusion sheet in which a plurality of approximately trapezoidalcolumnar unit lens portions are disposed, by removing the liquid resinfrom the mold for the diffusion sheet after it is set.

According to the tenth solving means of the present invention, since adiffusion sheet is manufactured using the mold for the diffusion sheetmanufactured according to the eight solving means, there can bemanufactured a diffusion sheet which achieves the same operation/workingeffect as that of the diffusion sheet according to the fifth solvingmeans described above likewise the ninth solving means described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing an example of a diffusion sheetaccording to a first embodiment of the present invention;

FIG. 2 is a sectional view showing the diffusion sheet shown in FIG. 1in detail;

FIG. 3A is a sectional view showing a light traveling direction in thediffusion sheet shown in FIGS. 1 and 2;

FIG. 3B is a graph showing the relation (gain curve) between a viewingposition (angle) and the brightness of an image (gain) in the diffusionsheet shown in FIG. 3A;

FIG. 4A is a sectional view showing an example of a diffusion sheetaccording to a second embodiment of the present invention;

FIG. 4B is a graph showing the relation (gain curve) between a viewingposition (angle) and the brightness of an image (gain) in the diffusionsheet shown in FIG. 4A;

FIG. 5 is a sectional view showing an example of a diffusion sheetaccording to a third embodiment of the present invention;

FIG. 6 is a sectional view showing a modification of the diffusionsheets according to the first to third embodiments of the presentinvention;

FIG. 7 is a sectional view showing another modification of the diffusionsheets according to the first to third embodiments of the presentinvention;

FIG. 8 is a sectional view showing still another modification of thediffusion sheets according to the first to third embodiments of thepresent invention;

FIG. 9 is a sectional view showing a further modification of thediffusion sheets according to the first to third embodiments of thepresent invention;

FIG. 10 is a sectional view showing an example of a rear projectionscreen provided with the diffusion sheet according to the first to thirdembodiments of the present invention;

FIG. 11 is a view explaining an example of a method of manufacturing amold for manufacturing the diffusion sheet shown in FIG. 6;

FIG. 12 is a perspective view showing an example of a diffusion sheetaccording to a fourth embodiment of the present invention;

FIG. 13A is a sectional view showing a light traveling direction in thediffusion sheet shown in FIG. 12;

FIG. 13B is a graph showing the relation (gain curve) between a viewingposition (angle) and the brightness of an image (gain) in the diffusionsheet shown in FIG. 13A;

FIG. 14 is a view explaining a first example of a method ofmanufacturing a mold for manufacturing the diffusion sheet according tothe fourth embodiment of the present invention;

FIG. 15 is a view explaining a second example of the method ofmanufacturing the diffusion sheet according to the fourth embodiment ofthe present invention;

FIG. 16 is a view explaining a third example of the method ofmanufacturing the diffusion sheet according to the fourth embodiment ofthe present invention;

FIG. 17 is a sectional view showing an example of a rear projectionscreen provided with the diffusion sheet according to the fourthembodiment of the present invention;

FIG. 18A is a sectional view showing a light traveling direction in aconventional diffusion sheet;

FIG. 18B is a graph showing the relation (gain curve) between a viewingposition (angle) and the brightness of an image (gain) in the diffusionsheet shown in FIG. 18A;

FIG. 19A is a sectional view showing an example of mold formanufacturing the conventional diffusion sheet;

FIG. 19B is a sectional view showing a light traveling direction in adiffusion sheet manufactured by the mold shown in FIG. 19A; and

FIG. 19C is a graph showing the relation (gain curve) between a viewingposition (angle) and the brightness of an image (gain) in the diffusionsheet shown in FIG. 19B.

EMBODIMENTS FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will be explained with reference tothe drawings.

Diffusion Sheet According to First Embodiment

First, a diffusion sheet according to a first embodiment of the presentinvention will be explained with reference to FIGS. 1, 2, 3A, and 3B.Note that the terms “right” and “left” used in the following explanationcorrespond to “right” and “left” when the diffusion sheet is assembledand used in a rear projection screen for a rear projection typetelevision.

As shown in FIG. 1, the diffusion sheet 101 according to the firstembodiment of the present invention has a plurality of unit lensportions 11 formed in an approximately trapezoidal columnar shape. Asshown in FIGS. 1 and 2, each unit lens portion 11 has a horizontalsection (surface obtained by cutting the unit lens portion 11 verticallywith respect to the long-axis direction thereof) formed in anapproximately trapezoidal shape, and has surfaces (side surfaces 111)corresponding to the side segments of the section, a lower bottomsurface (light incident surface 112) corresponding to the long bottomsegment of the section and an upper bottom surface (light outgoingsurface 113) corresponding to the short bottom segment of the section.In the trapezoidal section, both the bottom surfaces (that is, the upperand lower bottom surfaces) thereof are formed in parallel with eachother. Further, although there may be a case that the sections of theunit lens portions 11 are not formed in an accurate trapezoidal shape,explanation will be made in the description supposing that they areformed in the trapezoidal shape for the purpose of convenience. Notethat each unit lens portion 11 is also called a lenticular lens, and thediffusion sheet 101 is also called a lenticular lens sheet.

The unit lens portions 11 are continuously disposed on a transparentresin film substrate 22 so that the long axes thereof are in parallelwith each other. At the time, the unit lens portions 11 are disposedsuch that all the large surfaces (light incident surfaces 112 in FIG. 1)of the upper bottom surfaces and the lower bottom surfaces of the unitlens portions 11 are located on a light-incident-side flat surface (onthe surface of the transparent resin film substrate 22).

Further, a plurality of approximately triangle columnar light absorbingportions 12 are interposed between adjacent unit lens portions 11 toabsorb external light incident from a light outgoing side. Note that thelight absorbing portions 12 are also called black stripes.

Image light emitted from a light source (not shown) is incident on thediffusion sheet 101 arranged as described above from the light incidentsurfaces 112 of the unit lens portions 11 and outgoes from the lightoutgoing surfaces 113 thereof after it passes through the unit lensportions 11.

The unit lens portions 11 have the side surfaces 111 acting asboundaries between the unit lens portions 11 and the light absorbingportions 12 so that a part of light incident on the unit lens portions11 from the light incident sides thereof is totally reflected on theside surfaces 111. Accordingly, the refractive index n1 of the unit lensportion 11 and the refractive index n2 of the light absorbing portion 12must satisfy a relation of n1>n2, and thus the materials constitutingthe respective parts of the unit lens portions 11 and the lightabsorbing portions 12 are selected to satisfy the above relation.

Note that the material of the unit lens portions 11 is not particularlylimited as long as it satisfies the relation between the refractiveindices n1 and n2, and a resin and the like that are conventionally usedas the material of the lenticular lens can be used. Specifically, aradiation-setting type resin, a thermoplastic resin, and the like areexemplified. Among them, when the radiation-setting resin is used, it ispossible to mold the unit lens portions 11 faithfully to a mold shape.

In contrast, the light absorbing portions 12 prevent the reflection ofexternal light by absorbing and/or shielding external light, which isincident from the light outgoing side, and external light, which isincident on the unit lens portions 11 from the light outgoing surfaces113 thereof and reaches the side surfaces 111. The above function of thelight absorbing portions 12 prevents the deterioration of contrast of animage to be viewed.

Note that, the material of the light absorbing portions 12 is notparticularly limited as long as it satisfies the relation between therefractive indices n1 and n2, and a low refractive index acrylate resin,and the like to which, silicon, fluorine are introduced is used.Further, the light absorbing portions 12 may be added with lightabsorbing particles to absorb and/or to shield external light.Exemplified as the light absorbing particles are, for example, pigmentssuch as carbon, and the like, a plurality of dyes of red, blue, yellow,black, and the like or acrylic cross-linked particles colored with thepigments and/or the dyes, and the like.

Although the size of the diffusion sheet 101 arranged as described aboveis not particularly limited, it is ordinarily preferable that the sizebe about (50 cm long)×(70 cm wide)×(0.1 cm thick) to about (150 cmlong)×(200 cm wide)×(0.5 cm thick). Further, although the size of eachunit lens portion 11 is not particularly limited, it is ordinarilypreferable that the width of the light incident surface 112 be 50 to 80μm, the distance between the light incident surface 112 and the lightoutgoing surface 113 (lens height) be 100 to 170 μm, and the length inthe long-axis direction be 50 to 150 cm. It is possible to enhance theresolution of an image by miniaturizing the size of each unit lensportion 11 as described above.

The diffusion sheet 101 arranged as described above will be explainedbelow in detail with reference to FIGS. 2, 3A, and 3B.

As shown in FIG. 2, in the diffusion sheet 101, the distance (distancebetween the light incident surface 112 and the light outgoing surface113) h between both the bottom segments (long bottom segment and shortbottom segment) of the approximately trapezoidal section of each unitlens portion 11 is 120% or more to 400% or less of the length p of thelong bottom segment (light incident surface 112). The distance h betweenboth the bottom segments is preferably 200% or more to 400% or less ofthe length p of the long bottom segment (light incident surface 112),more preferably 200% or more to 250% or less of it, and most preferably200% or more to 230% or less of it. It is possible to stop down theoutgoing direction of light from the unit lens portions 11 of thediffusion sheet 101 as well as to easily absorb external light by thelight absorbing portions 12 by setting the value of h/p within the aboverange. Note that the upper limit value of h/p is set to 400% describedabove because an increase in the value of h/p deteriorates the removingproperty of the diffusion sheet 101 when it is removed from a mold afterit is molded as well as makes it difficult to manufacture the mold formolding the diffusion sheet 101. The length p of the long bottom segment(light incident surface 112) of the unit lens portions 11 is also calleda pitch. Further, the distance h between both the bottom segments (lightincident surface 112 and light outgoing surface 113) is also called thelens height.

In the diffusion sheet 101, it is preferable that the length w of thelight outgoing side bottom segment of the approximately triangularsection of each light absorbing portion 12 be 40% or more to 100% orless of the length p of the long bottom segment (light incident surface112) of the approximately trapezoidal section of each unit lens portion11. The length w is preferably 55% or more to 100% or less of the lengthp of the long bottom segment (light incident surface 112) of the unitlens portion 11, more preferably 55% or more to 70% or less of it, andmost preferably 55% or more to 65% or less of it. Since the ratio of thelight absorbing portions 12 interposed between the unit lens portions 11is increased by setting the value of w/p within the above range, thecontrast of an image can be enhanced, which permits the observer toeasily view the image. Further, setting the value of w/p within theabove range can excellently suppress the reflection of external lightsuch as illumination in a room, and the like on a screen.

Further, in the diffusion sheet 101, although the angle θ between thelong bottom segment (light incident surface 112) and the side segments(side surfaces 111 acting as the total reflection surfaces) of theapproximately trapezoidal section of each unit lens portion 11 is notparticularly limited, it is about 75° to 89°, and preferably about 80°to 84°.

According to the diffusion sheet 101 arranged as described above, thelight from the unit lens portions 11 of the diffusion sheet 101 outgoesmainly in three directions as shown in FIG. 3A. Note that the threedirections described here is a sum of one direction (L2) in which thelight travels straight without being reflected on the side surfaces 111of the unit lens portions 11 and two directions (L1, L3) in which thelight travels right and left at the angle near to the center after it isreflected on the side surfaces 111.

In the diffusion sheet 101 according to the first embodiment of thepresent invention, since the side surfaces 111 of the unit lens portions11 have a steep angle with respect to the light incident surfaces 112 asshown in FIGS. 2 and 3A, light reflected on the side surfaces 111outgoes at the angle near to the center. Accordingly, when the gainobtained by the diffusion sheet 101 is measured, a gain curve, whichshows brightness (gain) to a viewing angle in a horizontal direction(angle between a viewing direction and the normal direction of thesheet), is a curve which is gentle in its entirety with one peak at acenter as shown in FIG. 3B. As described above, the diffusion sheet 101has no large minimum value in the gain curve. Accordingly, when theobserver views an image from a light source (not shown) from the side ofthe light outgoing surfaces 113 of the unit lens portions 11 on a rearprojection screen, and the like provided with the diffusion sheet 101,the image is brightest when the observer views it from the front of thesheet, and the image gradually becomes darker as the angle between anormal to the sheet and a visual line increases. Accordingly, even ifthe observer moves in a horizontal direction, he or she does not viewthe image in extremely different brightness, thereby the observer caneasily view the image in a natural state. Further, even if the observerviews the image at rest, there is no irregular brightness in one imagesurface, and he or she can view the image excellent in brightuniformity, thereby the observer can easily view the image in thenatural state.

(Method of Manufacturing Diffusion Sheet)

Next, a method of manufacturing the diffusion sheet 101 according to thefirst embodiment of the present invention will be explained.

First, a mold (metal mold) for a diffusion sheet is prepared to mold theapproximately trapezoidal columnar unit lens portions 11. The mold ismanufactured by sequentially forming approximately trapezoidal columnarrecesses corresponding to the unit lens portions 11 on a mold materialby cutting it. The mold may be formed in a flat shape or in a rollshape. Among them, when the roll-shaped mold is manufactured, aroll-shaped mold material composed of a soft metal, and the like ismounted on a lathe, and the approximately trapezoidal columnar recessesare sequentially formed by cutting the mold material with a cuttingtool, and the like while turning the mold material.

Next, although the diffusion sheet is manufactured using the mold for adiffusion sheet manufactured as described above, there are three typesof methods as specific methods of molding the diffusion sheet.

A molding method using the roll-shaped mold will be explained as a firstmolding method. In this case, a PET film acting as a transparent filmsubstrate 22 of the diffusion sheet 101 is caused to pass between theroll-shaped mold fixed on a rotatable shaft and a roller as well as aliquid resin (ultraviolet-ray setting resin), which is composed of thematerial described above and forms the unit lens portions 11, is flownbetween the PET film and the roll-shaped mold. The resin is caused topass along the roll-shaped mold together with the PET film and molded inthe shape of the plurality of unit lens portions 11. After the PET filmand the resin are caused to pass between the roll-shaped mold and theroller, ultraviolet rays are illuminated onto the resin on the PET filmto thereby set the resin. Thereafter, a sheet composed of the set resinand the PET film is removed from the roll-shaped mold. The main portionof the diffusion sheet 101 is formed by continuously executing the aboveprocess.

A molding method using the flat-shaped mold will be explained as asecond molding method. In this case, the liquid resin (ultraviolet-raysetting resin), which is composed of the material described above andforms the unit lens portions 11, is applied (coated) on the flat-shapedmold so that it is buried therein, the PET film acting as thetransparent resin film substrate 22 is placed on the resin and pressed,and then ultraviolet-rays are illuminated onto the resin to thereby setthe resin. Thereafter, a sheet composed of the set resin and the PETfilm is removed from the mold, thereby the main portion of the diffusionsheet 101 is formed.

A molding method using the flat-shaped mold will be explained as a thirdmolding method. In this case, a sheet composed of a PET film and a resindisposed on the PET film is placed on the flat-shaped mold, the PET filmacting as the transparent resin film substrate 22 and having a thicknessof about 30 to 200 μm, and the resin being composed of the materialdescribed above and forming the unit lens portions 11. Next, the resinon the PET film is formed by the flat-shaped mold so that it is moldedand made to the approximately trapezoidal columnar unit lens portions11. Finally, the thus obtained sheet is removed from the mold, therebythe main portion of the diffusion sheet 101 is molded.

Thereafter, the material (black resin) for the light absorbing portions12 described above is applied (coated) in the grooves formed between theunit lens portions 11 of the sheet that is removed from the mold by anyof the first to third molding methods, thereby the light absorbingportions 12 are formed. The diffusion sheet 101 according to the firstembodiment of the present invention is manufactured by the methodsdescribed above.

Note that, in the first embodiment described above, the horizontalsection of each of the unit lens portions 11 constituting the diffusionsheet 101 is formed in an isosceles trapezoidal shape as shown in FIGS.2 and 3A. However, the shape of the section is not limited to theisosceles trapezoidal shape, and the section may be formed in varioustrapezoidal shapes as described later (refer to FIGS. 4A, 5, 6, and 7).

Diffusion Sheet According to Second Embodiment

Next, a diffusion sheet according to a second embodiment of the presentinvention will be explained with reference to FIGS. 4A and 4B. The basicarrangement of the diffusion sheet according to the second embodiment ofthe present invention is approximately the same as that of the firstembodiment shown in FIGS. 1, 2, 3A, and 3B except that the diffusionsheet includes at least two types of unit lens portions, which have adifferent angle between each side segment and a light-incident-side longbottom segment of an isosceles trapezoidal section, as a plurality ofunit lens portions. In the second embodiment shown in FIGS. 4A and 4B,the same portions as those of the first embodiment shown in FIGS. 1, 2,3A, and 3B are denoted by the same reference numerals and the detaileddescription of them is omitted.

As shown in FIG. 4A, the diffusion sheet 102 according to the secondembodiment of the present invention has a plurality of unit lensportions 11 formed in an approximately trapezoidal columnar shape. Thehorizontal section of each of the unit lens portions 11 (surface cutvertically with respect to the long-axis direction of the unit lensportion 11) is formed in an isosceles trapezoidal shape. The pluralityof unit lens portions 11 include at least two types of unit lensportions 11 a and 11 b which have a different angle between sidesurfaces 111, which correspond to the side segments of the unit lensportions 11 and act as total reflection surfaces, and the light incidentsurfaces 112 corresponding to the long bottom segments of the unit lensportions 11. Specifically, the unit lens portions 11 includes the unitlens portions 11 a in which the angle between side surfaces 111 a andlight incident surfaces 112 is set to θ1 and unit lens portions 11 b inwhich the angle between side surfaces 111 b and light incident surfaces112 is set to θ2 different from θ1. These unit lens portions 11 a and 11b are alternately disposed on a transparent resin film substrate 22.

According to the diffusion sheet 102 arranged as described above, thelight reflected on the side surfaces 111 a and 111 b of the unit lensportions 11 a and 11 b travels at different angles (θ1′ and θ2′) asshown in FIG. 4A. As a result, the light passing through the unit lensportions 11 a and 11 b outgoes in at least four directions, and outgoesin five directions in total when light, which travels straight andpasses through the diffusion sheet 102 as it is, is taken intoconsideration. Accordingly, when the gain obtained by the diffusionsheet 102 is measured, a gain curve, which shows brightness (gain) to aviewing angle in a horizontal direction (angle between a viewingdirection and the normal direction of the sheet), has at least fivepeaks (maximum values) of brightness corresponding to the respectivelight outgoing directions, as shown in FIG. 4B. Since the bottoms of thepeaks overlap, the gain curve is a right/left symmetrical gentle curvehaving a peak at a center in its entirety. As described above, since thegain curve of the diffusion sheet 102 has no large minimum value, whenan observer views an image from a light source (not shown) from the sideof the light outgoing surfaces 113 of the unit lens portions 11 in arear projection screen, and the like provided with the diffusion sheet102, a part of the image where it is viewed in an extremely dark stateis eliminated. Further, the diffusion sheet 102 arranged as describedabove has a plurality of light outgoing angles, it is possible toincrease a viewing angle on the side where the image is viewed.Accordingly, when the observer views the image from the front of therear projection screen, and the like provided with the diffusion sheet102, he or she can view the image which is symmetrical on the right sideand the left side and has a good distribution of brightness. Further,even if the observer views the image while moving in a horizontaldirection, he or she can view the image which less varies in brightnessand is excellent in bright uniformity. Further, even if the observerviews the image at rest at a position other than the position in thefront of the rear projection screen (however, a position within aviewing angle at which the image can be preferably viewed), he or shecan view the image excellent in the bright uniformity.

It should be noted that, in the second embodiment described above, thereare alternately disposed at least the two types of the unit lensportions 11 a and 11 b which have the different angles (θ1, θ2) betweenthe side surfaces 111 corresponding to the side segments and the lightincident surfaces 112 corresponding to the long bottom segments.However, the manner of disposing the unit lens portions 11 a and 11 b isnot limited to the above, and they may be periodically disposed in apredetermined set of unit lens portions 11 a and 11 b, for example, twounit lens portions 11 a, two unit lens portions 11 b, two unit lensportions 11 a, two unit lens portions 11 b, or they may be disposed atrandom. Further, there may be used and disposed at least three types ofthe unit lens portions each having a different angle between the sidesurfaces 111 corresponding to the side segments and the light incidentsurfaces 112 corresponding to the long bottom segments in any arbitrarymode as described above.

Further, in the second embodiment described above, the horizontalsection of each of the unit lens portions 11 a and 11 b (11)constituting the diffusion sheet 102 is formed in the isoscelestrapezoidal shape as shown in FIG. 4A. However, the shape of thehorizontal section is not limited thereto and may be formed in varioustrapezoidal shapes (FIGS. 6 and 7) described below. When the sidesurfaces 111 of the unit lens portions 11 are formed in a curved surfaceas shown in FIG. 7, the average angle between each side surface 111 andthe light incident surface 112 of each unit lens portion 11 correspondsto the angles θ1 and θ2 in the diffusion sheet 102 shown in FIG. 4A.Note that, when the side surface 111 is the curved surface, the averageangle is the value obtained by measuring the angle (acute angle) betweenthe straight line connecting both the ends of the side surfaces 111 andthe light incident surface 112.

Diffusion Sheet According to Third Embodiment

Next, a diffusion sheet according to a third embodiment of the presentinvention will be explained with reference to FIG. 5. The basicarrangement of the diffusion sheet according to the third embodiment ofthe present invention is approximately the same as that of the firstembodiment shown in FIGS. 1, 2, 3A, and 3B except that each of unit lensportions, which are used as a plurality of unit lens portions in thethird embodiment, has a first angle between one side segment and alight-incident-side long bottom segment and a second angle, which isdifferent from the first angle, between the other side segment and thelong bottom segment in an approximately trapezoidal section. In thethird embodiment shown in FIG. 5, the same portions as those of thefirst embodiment shown in FIGS. 1, 2, 3A, and 3B are denoted by the samereference numerals and the detailed description of them is omitted.

As shown in FIG. 5, a diffusion sheet 103 according to the thirdembodiment of the present invention has the plurality of unit lensportions 11 formed in an approximately trapezoidal columnar shape.

The horizontal section of each of the unit lens portions 11 (surface cutvertically with respect to the long-axis direction of the unit lensportion 11) is formed in an nonisosceles trapezoidal shape.Specifically, in the horizontal section of each unit lens portion 11,the first angle θ3 between a side surface 111 c corresponding to oneside segment and a light incident surface 112 corresponding to a longbottom segment is different from the second angle θ4 between a sidesurface 111 d corresponding to the other side segment and the lightincident surface 112 corresponding to the long bottom segment. Theplurality of unit lens portions 11 each having the two types of theangles (θ3, θ4) are disposed on a transparent resin film substrate 22 insuch a manner that the surfaces, which correspond to the side segmentshaving the angle θ3, of adjacent unit lens portions 11 are disposedadjacent to each other, and the surfaces, which correspond to the sidesegments having the angle θ4, of adjacent unit lens portions 11 aredisposed adjacent to each other.

According to the diffusion sheet 103 arranged as described above, lightreflected on the side surfaces 111 c and 111 d of each unit lens portion11 travels at the different angles (θ3′ and θ4′) as shown in FIG. 5. Asa result, the light passing through each unit lens portion 11 outgoes inat least four direction, and outgoes in at least five directions intotal when light, which travels straight and passes through thediffusion sheet 103 as it is, is taken into consideration. Accordingly,when the gain obtained by the diffusion sheet 103 is measured, a gaincurve similar to that of the second embodiment described above isobtained (refer to FIG. 4B). As described above, since the gain curve ofthe diffusion sheet 103 has no large minimum value, when an observerviews an image from a light source (not shown) from the side of thelight outgoing surface 113 of the unit lens portions 11, a part of theimage where it is viewed in an extremely dark state is eliminated.Further, the diffusion sheet 103 arranged as described above has theplurality of light outgoing angles, it is possible to increase a viewingangle on the side where the image is viewed. Accordingly, when theobserver views the image from the front of the rear projection screen,and the like provided with the diffusion sheet 103, he or she can viewthe image which is right/left symmetrical and has a good distribution ofbrightness. Further, even if the observer views the image while movingin a horizontal direction, he or she can view the image which lessvaries in brightness and is excellent in bright uniformity. Further,even if the observer views the image at rest at a position other thanthe position in the front of the rear projection screen (however, aposition within a viewing angle at which the image can be preferablyviewed), he or she can view the image excellent in the brightuniformity. Further, when the diffusion sheet 103 as shown in FIG. 5 ismolded, it is possible to simplify the shape of a cutting tool forcutting a mold for the diffusion sheet, thereby the cutting tool can beeasily manufactured. Further, the mold and the cutting tool are lessbroken due to the insufficient strength of the cutting tool. A moldhaving a sufficient strength can be safely cut and manufactured byforming the diffusion sheet 103 in the shape described above.

It should be noted that, in the third embodiment described above, theplurality of unit lens portions 11 each having the two types of theangles (θ3 and θ4) are disposed in such a manner that the surfaces,which correspond to the segments having the angle θ3, of adjacent unitlens portions 11 are disposed adjacent to each other, and the surfaces,which correspond to the segments having the angle θ4, of adjacent unitlens portions 11 are disposed adjacent to each other. However, themanner of disposing the unit lens portions 11 is not limited to theabove manner, and they can be disposed in any arbitrary manner.Specifically, it is also possible, for example, to further combine anddispose other type of unit lens portions in each of which the anglesbetween the side surfaces 111 and the light incident surface 112 aredifferent from the angles described above (θ3 and θ4). However, even ifa diffusion sheet having a shape different from that of the diffusionsheet 103 shown in FIG. 5 is used, it is preferable to employ a mode ofthe unit lens portions and a manner of disposing them such that an imagehaving right/left symmetrical brightness can be obtained when an imagesurface is viewed in its entirety from the front of the diffusion sheet.

Further, in the third embodiment described above, the horizontal sectionof each unit lens portion 11 constituting the diffusion sheet 103 isformed in the non-isosceles trapezoidal shape as shown in FIG. 5.However, the shape of the horizontal section is not limited thereto andmay be formed in the various trapezoidal shapes (FIGS. 6 and 7)described below. When the side surfaces 111 of the unit lens portions 11are formed in a curved surface as shown in FIG. 7, the average anglebetween the side surface 111 and the light incident surface 112 of thehorizontal section of each unit lens portion 11 corresponds to theangles θ3 and θ4 in the diffusion sheet 103 shown in FIG. 5. Note that,when the side surface 111 is the curved surface, the average angle isthe value obtained by measuring the angle (acute angle) between thestraight line connecting both the ends of the side surface 111 and thelight incident surface 112.

Modifications of Diffusion Sheets According to First to ThirdEmbodiments

(First Modification)

In the diffusion sheets 101, 102, and 103 according to the first tothird embodiments described above, the horizontal trapezoidal section ofeach unit lens portion 11 constituting these diffusion sheets may beformed in such a shape that at least one side segment (side surface 111)of the horizontal trapezoidal section is formed in a broken-line shapebroken at one or more points d as shown by a diffusion sheet 104 of FIG.6. Specifically, the side surface 111 (total reflection surface), whichcorresponds to one side segment of the section of each unit lens portion11 is divided into a side surface 111 e on a light incident surface 112side and a side surface 111 f on a light outgoing surface 113 side bythe base point d. The angle θ5 of one side surface 111 between the sidesurface 111 e on the light incident surface 112 side and the lightincident surface 112 is different from the angle θ6 on the same sidesurface 111 between the side surface 111 f on the light outgoing surface113 side and the light incident surface 112.

According to the diffusion sheet 104 arranged as described above, sincethe side surface 111 acting as the total reflection surface has theplurality of flat surfaces 111 e and 111 f each having a different slantangle, light reflected on one side surface 111 travels at differentangles (θ5′ and θ6′), thereby the number of traveling directions oflight is increased. Accordingly, when both the side surfaces 111 of eachunit lens portion 11 are arranged in the same manner, a gain curveshowing brightness (gain) to a viewing angle in a horizontal direction(angle between a viewing direction and the normal direction of thesheet) has at least five peaks (maximum values). Further, since theangles at which the respective peaks are obtained are near to eachother, the angles at which the peaks are obtained are near to eachother, thereby the bottoms of the peaks overlap more effectively. As aresult, when the gain of the diffusion sheet 104 is measured, a curve,which is very gentle in its entirety and has a peak at a center, isobtained, thereby an image having better bright uniformity can beobtained.

A mold for molding the diffusion sheet 104 can be manufactured using,for example, cutting tools 60A and 60B as shown in, for example, FIG.11. The cutting tool 60A has an angle (180°−θ6) on one side of the tipthereof in accordance with the angle θ6 between the side surface 111 fand the light incident surface 112 and an angle (180°−θ5) on the otherside of the tip in accordance with the angle θ5 between the side surface111 e and the light incident surface 112. Further, the cutting tool 60Bhas an angle (180°−θ5) on one side of the tip thereof in accordance withthe angle θ5 between the side surface 111 e and the light incidentsurface 112, and an angle (180°−θ6) on the other side of the tip inaccordance with the angle θ6 between the side surface 111 f and thelight incident surface 112. As a specific method of manufacturing themold, first, a mold material 62 is cut using the cutting tool 60A andforms a surface 111 f′ (angle θ6) corresponding to the right sidesurface 111 f of the approximately trapezoidal section and a surface 111e′ (angle θ5) corresponding to the left side surface 111 e thereof(reference numeral (1) of FIG. 11). Next, the same position of the moldmaterial 62 is cut using the cutting tool 60B and forms a surface 111 e′(angle θ5) corresponding to the right side surface 111 e of theapproximately trapezoidal section and a surface 111 f′ (angle θ6)corresponding to the left side surface 111 f thereof (reference numeral(2) of FIG. 11). The mold for molding the diffusion sheet 104 can bemanufactured by cutting the same position of the mold material 62 usingthe cutting tools 60A and 60B as described above.

Note that although both the side surfaces 111 of the unit lens portion11 are formed in the broken line shape in FIG. 6, only one side surface111 thereof may be formed in the broken line shape depending on a unitlens portion 11. Although only the unit lens portions 11 each having thetwo types of the angles (θ5 and θ6) are continuously disposed in FIG. 6,the first modification is not limited thereto, and unit lens portionshaving a combination of other angles may be combined and disposed.Further, although each side segment (the side surface 111) is formed inthe shape projecting inward in the approximately trapezoidal section inFIG. 6, the first modification is not limited thereto, and it may beformed in a shape projecting outward. Furthermore, although each sidesurface 111 of the unit lens portion 11 is provided with the base pointd so that it has the two types of the angle in FIG. 6, the firstmodification is not limited thereto, and each side surfaces 111 may beprovided with at least two base points d so that it has at least threetypes of the angle. However, even if a diffusion sheet having a shapedifferent from that of the diffusion sheet 104 shown in FIG. 6 is used,it is preferable to employ a mode of the unit lens portions and a mannerof disposing them such that an image having right/left symmetricalbrightness can be obtained when an image surface is viewed in itsentirety from the front of the diffusion sheet.

(Second Modification)

In the diffusion sheets 101, 102, and 103 according to the first tothird embodiments described above, the horizontal trapezoidal section ofeach unit lens portion 11 constituting these diffusion sheets may beformed in a such shape that at least one side segment (side surface 111)of the horizontal trapezoidal section is formed in a curved state asshown by a diffusion sheet 105 of FIG. 7. Specifically, a side surface111 (total reflection surface) 111 g (111) corresponding to one sidesegment of the section of each unit lens portion 11 is composed of acurved surface.

According to the diffusion sheet 105 arranged as described above, sincethe side surface 111 g (111) acting as the total reflection surface iscomposed of the curved surface, when parallel light is incident on theside surface 111 g from a light incident surface 112, the reflectingangle of the parallel light is different depending on a position of theside surface 111 g, thereby the number of traveling directions of thelight (light outgoing directions) is increased after the light isreflected. Accordingly, when the gain of the diffusion sheet 105 ismeasured, a curve, which is very gentle in its entirety and has a peakat a center, is obtained, thereby an image having better brightuniformity can be obtained.

It should be noted that, although both the side segments (side surfaces111) of the approximately trapezoidal section are formed in the shapeprojecting inward in FIG. 7, the second modification is not limitedthereto, and both the side segments of the approximately trapezoidalsection may be formed in a shape projecting outward. Otherwise, one sidesegment of the approximately trapezoidal section may be formed in theshape projecting inward, and the other side segment may be formed in theshape projecting outward. Further, all the side segments (side surfaces111) need not be formed in the same shape and may be formed in adifferent shape in the unit lens portions 11. In the latter case, lightreflected by the side surfaces 111 can be caused to travel in variousdirections, thereby the brightness of an image can be made more uniform.However, even if a diffusion sheet having a shape different from that ofthe diffusion sheet 105 shown in FIG. 7 is used, it is preferable toemploy a mode of the unit lens portions and a manner of disposing themsuch that an image having right/left symmetrical brightness can beobtained when an image surface is viewed in its entirety from the frontof the diffusion sheet.

(Third Modification)

In the diffusion sheets 101, 102, and 103 according to the first tothird embodiments described above, it is preferable that the horizontalsection (surface cut vertically with respect to the long-axis directionof the unit lens portion 11) of each of the light absorbing portions 12formed between adjacent unit lens portions 11 be formed in anapproximately triangular shape as shown in a diffusion sheet 106 shownin FIG. 8 and that the light incident side vertex of the section becomposed of a straight line having a predetermined width (refer toreference numeral 121). Further, it is preferable that the width of thestraight line of the light incident side vertex be 2 μm or more to 10 μmor less.

Further, the light incident side vertex of each of the light absorbingportions 12 formed between the adjacent unit lens portions 11 may becomposed of a curved line (refer to reference numeral 122) as shown in adiffusion sheet 107 of FIG. 9. It is preferable that the radius ofcurvature of the curved line of the light incident side vertex be 1 μmor more to 5 μm or less. The curved lines (curved surfaces) of the lightincident side vertexes of the diffusion sheet 107 shown in FIG. 9 can beformed by plating, when a mold for molding the diffusion sheet 107 ismanufactured, the portions of the mold corresponding to vertex positions122 of the diffusion sheet 107, and then molding the diffusion sheet 107using the thus manufactured mold.

According to the diffusion sheets 106 and 107 arranged as describedabove, the extreme ends of the projections of the mold, which molds agroup of the unit lens portions of the diffusion sheets, need not bemade steep. Accordingly, the strength of the projections of the mold canbe enhanced, thereby the projections of the mold can be prevented fromtilting right and left.

Rear Projection Screen Provided with Diffusion Sheets According to Firstto Third Embodiments

The diffusion sheets 101 to 107 according to the first to thirdembodiments and the modifications thereof described above can be usedtogether with a Fresnel lens sheet 30 disposed on the light incidentside of the diffusion sheets 101 to 107, thereby a rear projectionscreen 50 is arranged as shown in FIG. 10.

The rear projection screen 50 provided with any one of the diffusionsheets 101 to 107 will be schematically explained below with referenceto FIG. 10. Note that FIG. 10 is a sectional view of the rear projectionscreen 50 in use when it is viewed from above an upper surface thereof.

As shown in FIG. 10, the rear projection screen 50 is provided with anyone of the diffusion sheets 101 to 107 (hereinafter, simply referred toas the diffusion sheets 101 to 107) and the Fresnel lens sheet 30disposed on the light incident side thereof. The rear projection screen50 is used in a rear projection type television, and the like. Further,the Fresnel lens sheet 30 adjusts image light emitted from a lightsource (not shown) of an image projector, and the like so that it ismade to approximate parallel light and introduces the approximatelyparallel light to the diffusion sheets 101 to 107. The approximatelyparallel light outgoing from the Fresnel lens sheet 30 is approximatelyvertically incident on the diffusion sheets 101 to 107, passes throughthe unit lens portions 11 of the diffusion sheet or is reflected on theside surfaces 111 thereof as described above, and outgoes in respectivelight outgoing directions. The Fresnel lens sheet 30 is not limited tothe shape shown in FIG. 10 and may be formed in any arbitrary shape aslong as it has a function for causing the image light, which is emittedfrom the light source (not shown) of the image projector in enlargement,to outgo as approximately parallel light as well as causing theapproximately parallel light to be approximately vertically incident onthe diffusion sheets 101 to 107.

According to the rear projection screen 50 arranged as described above,there can be provided a display on which an observer can view an imagewhich has no irregular brightness in an image surface, has good brightuniformity therein, and can be easily viewed even if the observer movesin a horizontal direction, or even if the observer views the image atrest from the front of the rear projection screen 50 or at a positionother than the front (however, a position within a viewing angle atwhich the image can be preferably viewed).

As shown in FIG. 10, it is preferable to dispose a support plate 21containing a diffusion agent on the light outgoing surface 113 side ofthe unit lens portions 11 of the diffusion sheets 101 to 107. Since theunit lens portions 11 of the diffusion sheets 101 to 107 are formed inthe approximately trapezoidal columnar shape and the light outgoingsurfaces 113 are formed flat, the support plate 21 can be joined to thelight outgoing surfaces 113 without a problem. Disposition of thesupport plate 21 as described above permits a reflection preventionlayer 23 and a surface hardened layer 24 to be formed on thelight-outgoing-side surface of the diffusion sheets 101 to 107, thereflection prevention layer 23 being subjected to a reflectionprevention treatment, and the surface hardened layer 24 being subjectedto a surface hardening treatment. Note that these layers are disposed onthe light-outgoing-side surface of the diffusion sheets 101 to 107through the support plate 21. Among these layers, the reflectionprevention layer 23 can preferably suppress the reflection of externallight such as illumination in a room, and the like on the screen.Further, even if the screen is touched with a finger, and the like orwiped for cleaning, the surface of the screen is resistant to scratchesdue to the surface hardened layer 24.

In the rear projection screen 50 arranged as described above, light,which outgoes from the unit lens portions 11 of the diffusion sheets 101to 107 and travels in one direction, is refracted when it is incident onand outgoes from the particles of the diffusion agent contained in thesupport plate 21 and further is reflected on the outside surfaces of theparticles of the diffusion agent and diffused, thereby the light travelsin a plurality of directions. Accordingly, the irregular brightness ofan image due to a position of the observer can be reduced. The diffusionagent, which is referred to here, is particles composed of a resin, andthe like having a refractive index different from that of the resin, andthe like that forms the support plate 21, and the particles arescattered in the support plate 21. Acrylic cross-linked beads, glassbeads, and the like are used as the diffusion agent. When the supportplate 21 is disposed on the diffusion sheets 101 to 107, peaks (maximumvalues) other than the peak at the center of the gain curve describedabove can be eliminated by the diffusion of the particles of thediffusion agent.

Further, it is preferable in the rear projection screen 50 to make thelight-outgoing-side surface of the support plate 21 flat. Making thelight-outgoing-side surface of the support plate 21 flat permits theobserver to easily view an image because the image can be expressed flatwithout distortion. Further, since the surfaces of the diffusion sheets101 to 107 are not curved and have no irregularities, the surfaces canbe simply wiped by hand, thereby it is possible to make the surfaces ofthe diffusion sheets 101 to 107 free from scratches and dusts.

Further, it is preferable in the rear projection screen 50 to providethe support plate 21 with an ultraviolet ray absorbing action bycontaining an ultraviolet ray absorption agent in the support plate 21.With this arrangement, ultraviolet rays included in external light canbe absorbed by the support plate 21, thereby deterioration (colorchange, quality deterioration, and the like) of a plastic materialconstituting the unit lens portions 11, and the like in the diffusionsheets can be prevented. Note that, when a material, which forms thesupport plate 21, has the ultraviolet ray absorbing action by itself, itis not always necessary for the support plate 21 to separately containthe ultraviolet ray absorption agent. An acrylic acid ester resin, andthe like can be used to form the support plate 21 as a material havingthe ultraviolet ray absorbing action. Further, when a resin, which isunlikely to absorb ultraviolet rays, is used as a material for formingthe support plate 21, it is preferable to contain benzophenone,benzotriazole, or acrylate or salicylate ultraviolet ray absorbing agentin the support plate 21.

Diffusion Sheet According to Fourth Embodiment

Next, a diffusion sheet according to a fourth embodiment of the presentinvention will be explained with reference to FIGS. 12, 13A, and 13B.Note that the terms “right” and “left” used in the following explanationcorrespond to “right” and “left” when the diffusion sheet is assembledand used in a rear projection screen for a rear projection typetelevision.

As shown in FIG. 12, the diffusion sheet 201 according to the fourthembodiment of the present invention has a plurality of unit lensportions 211 formed in an approximately trapezoidal columnar shape. Asshown in FIGS. 12 and 13A, each unit lens portion 211 has a horizontalsection (surface obtained by cutting the unit lens portion 211vertically with respect to the long axis direction thereof) formed in anapproximately trapezoidal shape, and has surfaces (side surfaces 311)corresponding to the side segments of the section, a lower bottomsurface (light incident surface 312) corresponding to the long bottomsegment of the section and an upper bottom surface (light outgoingsurface 313) corresponding to the short bottom segment of the section.In the trapezoidal section, both the bottom surfaces (that is, the upperand lower bottom surfaces) thereof are formed in parallel with eachother. Further, although there may be a case that the sections of theunit lens portions 211 are not formed in an accurate trapezoidal shape,explanation will be made in the description supposing that they areformed in the trapezoidal shape for the purpose of convenience. Notethat each unit lens portion 211 is also called a lenticular lens, andthe diffusion sheet 201 is also called a lenticular lens sheet.

The unit lens portions 211 are continuously disposed on a transparentresin film substrate 222 so that the long axes thereof are in parallelwith each other. At the time, the unit lens portions 211 are disposedsuch that all the large surfaces (light incident surfaces 312 in FIG.12) of the upper bottom surfaces and the lower bottom surfaces of theunit lens portions 211 are located on a light-incident-side flat surface(on the surface of the transparent resin film substrate 222).

Further, a plurality of approximately triangle columnar light absorbingportions 212 are interposed between adjacent unit lens portions 211 toabsorb external light incident from a light outgoing side. Note that thelight absorbing portion 212 are also called black stripes.

Image light emitted from a light source (not shown) is incident on thediffusion sheet 201 arranged as described above from the light incidentsurface 312 of the unit lens portions 211 and outgoes from the lightoutgoing surface 313 thereof after it passes through the unit lensportions 211.

The unit lens portions 211 have the side surfaces 311 composed of curvedsurfaces and acting as boundaries between the unit lens portions 211 andthe light absorbing portions 212 so that a part of the light incident onthe unit lens portions 211 from the light incident side thereof istotally reflected on the side surfaces 311 a and 311 b (311).Accordingly, the refractive index n1 of the unit lens portion 211 andthe refractive index n2 of the light absorbing portion 212 must satisfya relation of n1>n2, and thus the materials constituting the respectiveparts of the unit lens portions 211 and the light absorbing portion 212are selected to satisfy the above relation.

Note that the material of the unit lens portions 211 is not particularlylimited as long as it satisfies the relation between the refractiveindices n1 and n2, and a resin and the like that are conventionally usedas the material of the lenticular lens can be used. Specifically, aradiation-setting type resin, a thermoplastic resin, and the like, forexample, can be exemplified. Among them, when the radiation-settingresin is used, it is possible to mold the unit lens portions 211faithfully to a mold shape.

In contrast, the light absorbing portions 212 prevent the reflection ofexternal light by absorbing and/or shielding external light, which isincident from the light outgoing side, and external light, which isincident on the unit lens portions 211 from the light outgoing surfaces313 thereof and reaches the side surfaces 311. The above function of thelight absorbing portions 212 prevents the deterioration of contrast ofan image to be viewed.

Note that, the material of the light absorbing portions 212 is notparticularly limited as long as it satisfies the relation between therefractive indices n1 and n2, and a low refractive index acrylate resin,and the like to which, silicon, fluorine, and the like are introducedcan be used. Further, the light absorbing portions 212 may be added withlight absorbing particles to absorb and/or shield external light.Exemplified as the light absorbing particles are, for example, pigmentssuch as carbon, and the like, a plurality of dyes of red, blue, yellow,black, and the like or and/or acrylic cross-linked particles coloredwith the pigments and/or the dyes, and the like.

Although the size of the diffusion sheet 201 arranged as described aboveis not particularly limited, it is ordinarily preferable that the sizebe about (50 cm long)×(70 cm wide)×(0.1 cm thick) to (150 cm long)×(200cm wide)×(0.5 cm thick). Further, although the size of the unit lensportions 211 is not particularly limited, it is ordinarily preferablethat the width of the light incident surface 312 be 50 to 80 μm, thedistance between the light incident surface 312 and the light outgoingsurface 313 (lens height) be 100 to 170 μm, and the length in thelong-axis direction be 50 to 150 cm. It is possible to enhance theresolution of an image by miniaturizing the size of each unit lensportion 211 as described above.

The diffusion sheet 201 arranged as described above will be explained indetail with reference to FIGS. 13A, and 13B.

As shown in FIG. 13A, the diffusion sheet 201 is composed of unit lensportions 211 a and unit lens portions 211 b disposed thereincontinuously and alternately, each of the unit lens portions 211 havingan approximately trapezoidal section both the side segments (sidesurfaces 311 a) of which are composed of curved lines projecting inward,and each of the unit lens portions 211 b having an approximatelytrapezoidal section both the side segments (side surfaces 311 b) ofwhich are composed of curved lines projecting outward. Accordingly, inthe diffusion sheet 201, the plurality of side segments 311 of thesections of the unit lens portions 211 a and 211 b (211) includes, as awhole, both the side segments (side surfaces 311 a) each composed of thecurved line projecting inward and the side segments (side surfaces 311b) each composed of the curved line projecting outward. In the diffusionsheet 201, the number of the side segments (side surfaces 311 a) eachcomposed of the curved line projecting inward in the section of eachunit lens portion 211 a is approximately the same as the number of theside segments (side surfaces 311 b) each composed of the curved lineprojecting outward in the section of each unit lens portions 211 b as awhole. Further, in the diffusion sheet 201, the number of right sidesegments (right side surfaces 311 a) each composed of the curved lineprojecting inward is approximately the same as the number of left sidesegments (left side surfaces 311 a) each composed of the curved lineprojecting inward, and the number of right side segments (right sidesurfaces 311 b) each composed of the curved line projecting outward isapproximately the same as the number of left side segments (left sidesurfaces 311 b) each composed of the curved line projecting outward.

Further, in the diffusion sheet 201, although the average angle betweenthe long bottom segment (light incident surface 312) and each sidesegment (side surface 311 acting as the total reflection surface) of theapproximately trapezoidal section of each unit lens portion 211 is notparticularly limited, it is about 75° to 89° and preferably about 80° to84°. The average angle is the value obtained by measuring the angle(acute angle) between the straight line connecting both the ends of theside surface 311 acting as the total reflection surface and the lightincident surface 312. Note that a reason why the average angle ismeasured is in that when the side segment 311 acting as the totalreflection surface is composed of the curved surface, an accurate anglecannot be specified.

According to the diffusion sheet 201 arranged as described above, lightfrom the unit lens portions 211 a and 211 b (211) of the diffusion sheet201 outgoes mainly in five directions as shown in FIG. 13B. The fivedirections referred to here is a total of one direction (L1, L4) inwhich light travels straight without being reflected on the sidesurfaces 311 a and 311 b (311) of the unit lens portions 211, twodirections (L2 and L3) in which light travels right and left at an angleapart from a center by being reflected on the side surfaces 311 aprojecting inward, and two directions (L5 and L6) in which light travelsright and left at an angle near to the center by being reflected on theside surfaces 311 b projecting outward. Since each of the side surfaces311 a and 311 b (311) acting as the total reflection surfaces iscomposed of the curved surface, actually, light reflected on the sidesurfaces 311 a and 311 b (311) does not entirely outgo in the samedirection. However, it is assumed here that the outgoing light travelsin the respective outgoing directions (L2, L3, L5, and L6) as thecentral outgoing directions thereof. Accordingly, when the gain obtainedby the diffusion sheet 201 is measured, a gain curve, which showsbrightness (gain) to a viewing angle in a horizontal direction (anglebetween a viewing direction and the normal direction of the sheet), hasat least five peaks (maximum values) of brightness corresponding to therespective light outgoing directions. Since the bottoms of the peaksoverlap, the gain curve is a right/left symmetrical gentle curve havinga peak at a center in its entirety as shown in FIG. 13B. As describedabove, in the diffusion sheet 201, the gain curve can be improved to thegentle right/left symmetrical curve. Accordingly, when an observer viewsan image from a light source (not shown) from the side of the lightoutgoing surfaces 313 of the unit lens portions 211 a and 211 b (211),the image is brightest when the observer views it from the front of thesheet surface, and the image gradually becomes darker as the anglebetween a normal to the sheet surface and a visual line increases.Accordingly, even if the observer moves in a horizontal direction, he orshe does not view the image in extremely different brightness, therebythe observer can easily view the image in a natural state. Further, evenif the observer views the image at rest, there is no irregularbrightness in one image surface, and he or she can view the imageexcellent in bright uniformity without irregular brightness, thereby theobserver can easily view the image in the natural state.

(Method of Manufacturing Diffusion Sheet)

Next, a method of manufacturing the diffusion sheet 201 according to thefourth embodiment of the present invention will be explained.

First, a mold (metal mold) for a diffusion sheet is prepared to mold theapproximately trapezoidal columnar unit lens portions 211. The mold maybe formed in a flat shape or in a roll shape. A method of manufacturingthe mold for a diffusion sheet will be explained in detail later.

Next, although the diffusion sheet is manufactured using the mold for adiffusion sheet manufactured as described above, there are two types ofmethods as specific methods of molding the diffusion sheet.

A molding method using the roll-shaped forming mold will be explained asa first molding method. In this case, a PET film acting as a transparentfilm substrate 222 of the diffusion sheet 201 is caused to pass betweenthe roll-shaped mold fixed on a rotatable shaft and a roller as well asa liquid resin (ultraviolet-ray setting resin), which is composed of thematerial described in the methods of manufacturing the diffusion sheetdescribed above and forms the unit lens portions 211, is flown betweenthe PET film and the roll-shaped mold. The resin is caused to pass alongthe roll-shaped mold together with the PET film and molded in the shapeof the plurality of unit lens portions 211. After the PET film and theresin are caused to pass between the roll-shaped forming mold and theroller, ultraviolet rays are illuminated onto the resin on the PET filmto thereby set the resin. Thereafter, a sheet composed of the set resinand the PET film is removed from the roll-shaped forming mold. The mainportion of the diffusion sheet 201 is formed by continuously executingthe above process.

A molding method using the flat-shaped forming mold will be explained asa second molding method. In this case, the liquid resin (ultraviolet-raysetting resin), which is composed of the material described above andforms the unit lens portions 211, is applied (coated) on the flat-shapedmold so that it is buried therein, the PET film acting as thetransparent resin film substrate 222 is placed on the resin and pressed,and then ultraviolet-rays are illuminated onto the resin to thereby setthe resin. Thereafter, a sheet composed of the set resin and the PETfilm is removed from the mold, thereby the main portion of the diffusionsheet 201 is formed.

Thereafter, the material (black resin) for the light absorbing portions212 described above is applied (coated) in the grooves formed betweenthe unit lens portions 211 of the sheet that is removed from the mold inany of the first and second molding methods, thereby the light absorbingportions 212 are formed. The diffusion sheet 201 according to the fourthembodiment of the present invention is manufactured by the methodsdescribed above.

The method of manufacturing the mold for the diffusion sheet describedabove will be explained with reference to FIGS. 14 to 16.

In general, the mold is manufactured by cutting a mold material to formapproximately trapezoidal recesses corresponding to the unit lensportions 211 therein. A deformation resistant material such as a steelmaterial and the like may be used as the mold material. However, whenthe deformation resistant material is used, a cutting tool, which willbe described later, is liable to be broken when it cuts the deformationresistant material. When the cutting tool is broken, productivity isgreatly deteriorated because cutting must be resumed from the beginning.Accordingly, it is preferable to use materials excellent inmachinability such aluminum, copper, nickel, and the like. When theroll-shaped mold is manufactured as the mold described above, aroll-shaped mold material composed of a soft metal, and the like ismounted on a lathe, and the approximately trapezoidal columnar recessesare sequentially formed by cutting the mold material with the cuttingtool, and the like while turning the mold material.

More specifically, a plurality of trapezoidal columnar recesses for unitlens portions are formed in the mold material alternately by cutting themold material while remaining spaces for trapezoidal columnar recessesfor unit lens portions at least each one of which is to be locatedadjacent to each of the above unit lens portions. Thereafter, theremaining spaces of the metal mold are cut to form trapezoidal columnarrecesses for the unit lens portions at least each of which is locatedadjacent to each of the above unit lens portions. Specific examples ofthe method of manufacturing the mold for the diffusion sheet describedabove will be explained below with reference to FIGS. 14 to 16.

First Example of Method of Manufacturing Mold for Diffusion Sheet

First, a first specific example of the method of manufacturing the moldfor the diffusion sheet will be explained with reference to FIG. 14.

As shown in a part (a) of FIG. 14, at a first step, a mold material 161is prepared, and the mold material 161 is cut to alternately formtrapezoidal columnar recesses (grooves) 162 for unit lens portions whileremaining spaces for recesses for unit lens portions each one of whichis to be located adjacent to each of the above unit lens portions. Whennumbers (1), (2), (3) . . . , are sequentially given to the spaces ofthe mold material 161 for the recesses of the unit lens portions fromthe space for the recess of the unit lens portion located at the leftend as shown in the part (a) of FIG. 14, the spaces of the mold material161 corresponding to the odd numbers are cut at the first step.

Next, as shown in a part (b) of FIG. 14, the remaining spaces of themold material 161 are cut likewise to form trapezoidal columnar recesses162 for unit lens portions at a second process. When the numbersdescribed above are referred to, the spaces of the mold material 161corresponding to the even numbers are cut at the second step.

When the trapezoidal columnar recesses 162 for the unit lens portionsare formed by cutting the mold material 161 as described above, a forceis naturally applied to the mold material 161. Accordingly, projections163 located on both the sides of the trapezoidal columnar recesses 162formed later tilt outward thereof (on the side of the recesses 162having been cut). As a result, the projections 163 formed between therecesses 162 tilt in the sequence of “left, right”, “left, right”,“left, right”, . . . on the section of a mold 601 as shown in the part(b) of FIG. 14. Note that, although the spaces corresponding to the oddnumbers are cut first in the above description, the spaces correspondingto the even number may be cut first. In the case, the projections 163formed between the recesses 162 of the mold material 161 also tilt leftand right in the approximately same sequence as the above case, therebythe number of the projections 163 which tilt left is approximately thesame as the number of the projections 163 which tilt right in the mold601 in its entirety.

Second Example of Method of Manufacturing Mold for Diffusion Sheet

Next, a second specific example of the method of manufacturing the moldfor the diffusion sheet will be explained with reference to FIG. 15.

As shown in a part (a) of FIG. 15, at a first step, a mold material 161is prepared, and the mold material 161 is cut to form trapezoidalcolumnar recesses (grooves) 162 for unit lens portions at intervals oftwo recesses while remaining spaces for recesses for unit lens portionseach two of which are to be located adjacent to each of the above unitlens portions. When numbers (1), (2), (3), . . . are sequentially givento the spaces of the mold material 161 for the recesses of the unit lensportions from the space for the recess of the unit lens portion locatedat the left end, the spaces corresponding to the numbers represented by(multiples of 3+1), for example, 1, 4, 7, 10, 13, . . . are cut at thefirst step.

Next, as shown in a part (b) of FIG. 15, at a second step, a trapezoidalcolumnar recess 162 for a unit lens portion is formed to one of eachremaining spaces for the recesses for two unit lens portions likewise.When the numbers described above are referred to, the spaces of the moldmaterial 161 corresponding to the numbers represented by multiples of 6and the numbers represented by (multiples of 6+2), for example, (2, 6,8, 12, 14, . . . ) are cut at the second step.

Next, as shown in a part (c) of FIG. 15, trapezoidal columnar recesses162 for unit lens portions are formed to the remaining spaces likewiseat a third process. When the numbers described above are referred to,the spaces corresponding to the numbers 3, 5, 9, 11, 15, . . . are cutat the third step.

When the trapezoidal columnar recesses 162 for the unit lens portionsare formed by cutting the mold material 161 as described above, a forceis naturally applied to the mold material 161. Accordingly, projections163 located on both the sides or on one side of the trapezoidal columnarrecesses 162 formed later tilt outward thereof (on the side of therecesses 162 having been cut). As a result, the projections 163 formedbetween the recesses 162 tilt in the sequence of “left, left, right,left, right, right”, “left, left, right, left, right, right”, . . . onthe section of a mold 602 as shown in the part (c) of FIG. 15. It shouldbe noted that the sequence in which the recesses 162 for the unit lensportions are formed is not limited to the one described above, and therecesses can be formed in any arbitrary sequence as long as the sequencein which the projections 163 formed between the recesses 162 for theunit lens portions tilt left and right is approximately the same as theabove sequence, and the number of the projections 163 which tilt rightis approximately the same as the number of the projections 163 whichtilt left in the mold 602 in its entirety.

Third Example of Method of Manufacturing Mold for Diffusion Sheet

Next, a third specific example of the method of manufacturing the moldfor the diffusion sheet will be explained with reference to FIG. 16.

As shown in a part (a) of FIG. 16, at a first step, a mold material 161is prepared, and the mold material 161 is cut to form trapezoidalcolumnar recesses (grooves) 162 for unit lens portions at intervals ofthree recesses while remaining spaces for recesses for three unit lensportions each three of which are to be located adjacent to each of theabove unit lens portions. When numbers (1), (2), (3), . . . aresequentially given to the spaces of the mold material 161 for therecesses of the unit lens portions from the space for the recess of theunit lens portion located at the left end, the spaces corresponding tothe numbers represented by (multiples of 4+1), for example, (1, 5, 9,13, 17, . . . ) are cut at the first step.

Next, as shown in a part (b) of FIG. 16, trapezoidal columnar recesses162 for unit lens portions are formed in the spaces, which are locatedon both the sides of each of the recesses 162 formed previously, of theremaining spaces for the recesses of each three unit lens portions. Whenthe numbers described above are referred to, the spaces corresponding tothe numbers represented by multiples of 2 (for example, 2, 4, 6, 8, 10,12, 14, 16, 18, . . . ) are cut at the second step.

Next, as shown in a part (c) of FIG. 16, at a third step, trapezoidalcolumnar recesses 162 for unit lens portions are formed in the remainingspaces likewise. When the numbers described above are referred to, thespaces of the mold material 161 corresponding to the numbers 3, 7, 11,15, 19, . . . are cut at the third step.

When the trapezoidal columnar recesses 162 for the unit lens portionsare formed by cutting the mold material 161 as described above, a forceis naturally applied to the mold material 161. Accordingly, projections163 located on both the sides or on one side of the trapezoidal columnarrecesses 162 formed later tilt outward thereof (on the side of therecesses 162 having been cut). As a result, the projections 163 formedbetween the recesses 162 tilt in the sequence of “left, left, right,right”, “left, left, right, right”, . . . on the section of a mold 603as shown in the part (c) of FIG. 16. It should be noted that thesequence in which the recesses 162 for the unit lens portions are formedis not limited to the one described above, and the recesses can beformed in any arbitrary sequence as long as the sequence in which theprojections 163 formed between the recesses 162 for the unit lensportions tilt left and right is approximately the same as the abovesequence, and the number of the projections 163 which tilt right isapproximately the same as the number of the projections 163 which tiltleft in the mold 603 in its entirety.

In the methods of manufacturing the mold for the diffusion sheetaccording to the first to third examples described above, there isexemplified the case that the projections 163 formed by cutting the moldmaterial 161 are deformed (plastically deformed) outward when they areviewed from recesses 162 being cut. However, the mold material 161 canbe cut by the same procedure even if the projections 163 formed bycutting the mold material 161 are deformed (elastically deformed) inwardwhen they are viewed from recesses 162 being cut, inversely to the abovecase. In the latter case, a mold for the diffusion sheet, which issimilar to that of the former case in its entirety, can be manufacturedalthough the projections 163 deform in an opposite direction. Further,the diffusion sheet according to the fourth embodiment of the presentinvention described above can be also molded by the mold of the lattercase. Note that, in the mold of the latter case, the projections 163formed between adjacent recesses 162 are formed in such a shape thatthey tilt from the side of the recesses 162 formed previously toward theside of the recesses 162 formed later.

In addition to the above molds, there may be manufactured a mold whichmolds a diffusion sheet having projections 163 both the sides of whichare formed in a curved shape by the cooperative action of the elasticdeformation and the plastic deformation of the mold material 161,although the projections 163 formed between adjacent recesses 162 is notformed in a tilt shape. Further, there is also a mold by which the sidesurfaces of the projections 163 formed between adjacent recesses 162 areformed in a flat shape in place of a curved shape because the moldmaterial 161 is neither elastically deformed nor plastically deformed bythe mold. The diffusion sheet according to the fourth embodimentdescribed above can be also molded by the molds as described above. Notethat the elastic deformation and the plastic deformation of the moldmaterial 161 are ordinarily varied depending on the cutting conditions(for example, a speed at which the mold material 161 is cut, the stateof the blade of a cutting tool, and the like) of the mold material 161.Accordingly, when the mold for the diffusion sheet is manufactured, itis preferable to confirm which of the elastic deformation and theplastic deformation occurs in the mold material 161 under the cuttingconditions thereof employed at the time. However, it is possible asdescribed above to manufacture a mold for molding a diffusion sheet inwhich the side surfaces of the projections 163 can be formed in adesired shape and tilt as desired by cutting mold material 161 by thesame cutting procedure regardless that the mold material 161 issubjected to any of the deformations.

It should be note that the method of manufacturing the mold for moldingthe diffusion sheet according to the fourth embodiment of the presentinvention is not limited to the manufacturing methods according to thefirst to third examples described above, and any other manufacturingmethods can be arbitrarily used as long as the number of the rightwardprojections formed between the recesses for the unit lens portions isapproximately the same as the number of the leftward projections formedbetween the recesses for the unit lens portions in the mold in itsentirety. It is preferable in the mold manufactured as described abovethat the projections formed between the recesses for the unit lensportions tilt symmetrically right and left as a whole. Further, it isalso preferable for the diffusion sheet molded by the above mold topermit light to uniformly outgo therefrom in the range of a wide angle(range from an angle near to a center to an angle apart from thecenter).

(Master Mold for Diffusion Sheet)

A master mold for the diffusion sheet can be manufactured by the sameprocedure as that of the method of manufacturing the mold for thediffusion sheet described above. The mold for the diffusion sheet may becopied using the master mold for the diffusion sheet manufactured asdescribed above, and then the diffusion sheet may be molded using thethus copied mold.

Specifically, first, the master mold is manufactured by the sameprocedure as the method of manufacturing the mold described above. Next,a first forming layer composed of nickel, and the like is formed on asurface of the master mold manufactured as described above by, forexample, electroforming, and the like. The first forming layer isremoved from the master mold and used as a mother mold. Next, a secondforming layer composed of nickel, and the like is formed on a surface ofthe mother mold by, for example, electroforming, and the like. Thesecond forming layer is removed from the mother mold and used as themold for molding the diffusion sheet after it is subjected to backing asnecessary. Since the mold manufactured as described above is formed inthe same shape as the master mold, it is formed in the same shape as themold manufactured by the method of manufacturing the mold describedabove.

Since a mold material of the master mold also has one or both of theplastically deforming characteristic and the elastically deformingcharacteristic described above, the master mold is manufacturedaccording to the characteristics so that the side surfaces of theprojections of the master mold are formed in a desired shape and tilt asdesired.

Rear Projection Screen Provided with Diffusion Sheet According to FourthEmbodiment

A diffusion sheet 201 according to the fourth embodiment can be usedtogether with a Fresnel lens sheet 230 disposed on the light incidentside of the diffusion sheets 201, thereby a rear projection screen 250is arranged as shown in FIG. 17.

The rear projection screen 250 provided with the diffusion sheet 201will be schematically explained below with reference to FIG. 17. Notethat FIG. 17 is a sectional view of the rear projection screen 250 inuse when it is viewed from above an upper surface thereof.

As shown in FIG. 17, the rear projection screen 250 is provided with thediffusion sheet 201 and the Fresnel lens sheet 230 disposed on the lightincident side thereof. The rear projection screen 250 is used in a rearprojection type television, and the like. Further, the Fresnel lenssheet 230 adjusts image light emitted from a light source (not shown) ofan image projector, and the like so that it is made to approximateparallel light and introduces the approximately parallel light to thediffusion sheet 201. The approximately parallel light outgoing from theFresnel lens sheet 230 is approximately vertically incident on thediffusion sheet 201, passes through the unit lens portions 211 of thediffusion sheet 201 or is reflected on the side surfaces 212 thereof andoutgoes in respective light outgoing directions. The Fresnel lens sheet230 is not limited to the shape shown in FIG. 17 and may be formed inany arbitrary shape as long as it has a function for causing the imagelight, which is emitted from the light source (not shown) of the imageprojector, and the like in enlargement, to outgo as approximatelyparallel light as well as causing the approximately parallel light to beapproximately vertically incident on the diffusion sheet 201.

According to the rear projection screen 250 arranged as described above,there can be provided a display on which an observer can view an imagewhich has no irregular brightness in an image surface, has good brightuniformity therein, and can be easily viewed even if the observer movesin a horizontal direction, or even if the observer views the image atrest from the front of the rear projection screen 250 or at a positionother than the front (however, a position within a viewing angle atwhich the image can be preferably viewed).

As shown in FIG. 17, it is preferable to dispose a support plate 221containing a diffusion agent on the light outgoing surface 313 side ofthe unit lens portions 211 of the diffusion sheet 201. Since the unitlens portions 211 of the diffusion sheet 201 are formed in theapproximately trapezoidal columnar shape and the light outgoing surfaces313 are formed flat, the support plate 221 can be joined to the lightoutgoing surfaces 313 without a problem. Disposition of the supportplate 221 as described above permits a reflection prevention layer 223and a surface hardened layer 224 to be formed on the light-outgoing-sidesurface of the diffusion sheet 201, the reflection prevention layer 223being subjected to a reflection prevention treatment, and the surfacehardened layer 224 being subjected to a surface hardening treatment.Note that these layers are disposed on the light-outgoing-side surfaceof the diffusion sheet 201 through the support plate 221. Among theselayers, the reflection prevention layer 223 can preferably suppress thereflection of external light such as illumination in a room, and thelike on the screen. Further, even if the screen is touched with afinger, and the like or wiped for cleaning, the surface of the screen isresistant to scratches due to the surface hardened layer 224.

In the rear projection screen 250 arranged as described above, light,which outgoes from the unit lens portions 211 of the diffusion sheet 201and travels in one direction, is refracted when it is incident on andoutgoes from the particles of the diffusion agent contained in thesupport plate 221 and further is reflected on the outside surfaces ofthe particles of the diffusion agent and diffused, thereby the lighttravels in a plurality of directions. Accordingly, the irregularbrightness of an image depending on a position of the observer can bereduced. The diffusion agent, which is referred to here, is particlescomposed of a resin, and the like having a refractive index differentfrom that of the resin, and the like that form the support plate 221,and the particles are scattered in the support plate 221. Acryliccross-linked beads, glass beads, and the like are used as the diffusionagent. When the support plate 221 is disposed on the diffusion sheet201, peaks (maximum values) other then the peak at the center of thegain curve described above can be eliminated by the diffusion of theparticles of the diffusion agent.

Further, it is preferable in the rear projection screen 250 to make thelight-outgoing-side surface of the support plate 221 flat. Making thelight-outgoing-side surface of the support plate 221 flat permits theobserver to easily view an image because the image can be expressed flatwithout distortion. Further, since the surface of the diffusion sheet201 is not curved and has no irregularities, the surface can be simplywiped by hand, thereby it is possible to make the surface of thediffusion sheet 201 free from scratches and dusts.

Further, it is preferable in the rear projection screen 250 to providethe support plate 221 with an ultraviolet ray absorbing action bycontaining an ultraviolet ray absorption agent in the support plate 221.With this arrangement, ultraviolet rays included in external light canbe absorbed by the support plate 221, thereby deterioration (colorchange, quality deterioration, and the like) of a plastic materialconstituting the unit lens portions 211, and the like in the diffusionsheet 201 can be prevented. Note that, when a material, which forms thesupport plate 221, has the ultraviolet ray absorbing action by itself,it is not necessary for the support plate 221 to separately contain theultraviolet ray absorption agent. An acrylic acid ester resin, and thelike can be used to form the support plate 221 as a material having theultraviolet ray absorbing action. Further, when a resin, which isunlikely to absorb ultraviolet rays, is used as a material for formingthe support plate 221, it is preferable to contain benzophenone,benzotriazole, or acrylate or salicylate ultraviolet ray absorbing agentin the support plate 221.

It should be noted that the fourth embodiment is arranged by alternatelydisposing the unit lens portions 211 a, in each of which both the sidesegments (side surfaces 311 a) of the approximately trapezoidal sectionare composed of curved line segments projecting inward, and the unitlens portions 211 b, in each of which both the side segments (sidesurfaces 311 b) of the approximately trapezoidal section are composed ofcurved line segments projecting outward. However, the manner ofdisposing the unit lens portions 211 a and 211 b are not limited to theabove, and they can be disposed in any manner other than the above aslong as light outgoes in approximately right/left symmetrical directionsas a whole. Accordingly, it is preferable in this case that the numberof the unit lens portions whose right side segments are composed of thecurved line segments projecting inward be approximately the same as thenumber of the unit lens portions whose left side segments are composedof the curved line segments projecting inward in the diffusion sheet 201in its entirety, and the number of the unit lens portions whose rightside segments are composed of the curved line segments projectingoutward be approximately the same as the number of the unit lensportions whose left side segments are composed of the curved linesegments projecting outward in the diffusion sheet 201 as a whole.

Further, the fourth embodiment is explained by exemplifying the casethat both the side segments (side surfaces 311) of the approximatelytrapezoidal section of each unit lens portion 211 are composed of thecurved line segments. However, one side segment of the approximatelytrapezoidal section may be composed of the curved line segment, and theother side segment may be composed of a straight line segment (that is,a side surface is a flat surface in place of a curved surface) as longas light outgoes in approximately right/left symmetrical directions as awhole. Accordingly, it is preferable in this case that the number of theside segments, which are composed of the curved line segments projectinginward, of the sections of the unit lens portions be approximately thesame as the number of the side segments, which are composed of thecurved line segments projecting outward, of the sections of the unitlens portions in the diffusion sheet as a whole, the number of the unitlens portions whose right side segments are composed of the curved linesegments projecting inward be approximately the same as number of theunit lens portions whose left side segments are composed of the curvedline segments projecting inward in the diffusion sheet as a whole, thenumber of the unit lens portions whose right side segments are composedof the curved line segments projecting outward be approximately the sameas number of the unit lens portions whose left side segments arecomposed of the curved line segments projecting outward in the diffusionsheet as a whole, and the number of the unit lens portions whose rightside segments are composed of the straight lines be approximately thesame as number of the unit lens portions whose left side segments arecomposed of the straight lines in the diffusion sheet as a whole.

Further, in the fourth embodiment described above, the horizontalsection of each unit lens portion 211 constituting the diffusion sheet201 is formed in the isosceles trapezoidal shape (the average angle ofthe side surfaces 311 is the same in the unit lens portion 211) as shownin FIGS. 2 and 3A. However, the shape of the horizontal section is notlimited thereto, and the horizontal section may be formed in atrapezoidal shape in which the average angle of the side surfaces 311 isdifferent in one unit lens portion 211.

EXAMPLES

Specific examples and comparative examples of the first to thirdembodiments described above will be explained below.

Example 1-1

A diffusion sheet as shown in FIGS. 1 and 2 was manufactured as adiffusion sheet according to an example 1-1.

Specifically, first, a roll-shaped metal mold was prepared bysequentially cutting a metal mold material to form recesses for unitlens portions so that a diffusion sheet, in which a plurality of unitlens portions were continuously disposed, was molded by the metal mold.The plurality of unit lens portions molded by the metal mold were suchthat the horizontal section of each of the unit lens portions was formedin an isosceles trapezoidal shape, the pitch p of the unit lens portionswas set to 70 μm, a lens height h was set to 140 μm, the ratio of thelength w of the light outgoing side bottom segment of the triangularsection of each light absorbing portion to the pitch p (w/p) was set to56%, and the angle θ between a light incident surface and a side surface(total reflection surface) was set to 82°.

A UV resin was buried in the roll-shaped metal mold prepared asdescribed above, and the diffusion sheet was manufactured using a PETfilm substrate having a thickness of 50 μm, wherein the UV resin had arefractive index n1 of 1.55 after it was set.

Thereafter, the light absorbing portions were formed in the V-shapedgrooves between the unit lens portions. The light absorbing portionswere formed using a light absorption agent composed of black beadsdispersed in an acrylic paint having a refractive index n2 of 1.49,wherein the black beads had an average particle size of 3 μm.

The diffusion sheet as shown in FIGS. 1 and 2 was manufactured by theprocedure described above. A support plate having a thickness of 2 mmand composed of an MS resin containing a dispersion agent and anultraviolet ray absorbent was bonded onto the light-outgoing-sidesurface of the thus manufactured diffusion sheet, and a rear projectionscreen was obtained by combining the diffusion sheet with aconventionally known Fresnel lens sheet.

Example 1-2

A diffusion sheet as shown in FIG. 4A was manufactured as a diffusionsheet according to an example 1-2.

Specifically, the diffusion sheet was formed in the shape shown in Table1 as a whole by alternately disposing two types of isosceles trapezoidalcolumnar unit lens portions, that is, one type of the isoscelestrapezoidal columnar unit lens portion had an angle θ1 of 80° between alight incident surface and each side surface (total reflection surface),and the other type of the isosceles trapezoidal columnar unit lensportion had an angle θ2 of 82° between a light incident surface and eachside surface (total reflection surface). The diffusion sheet as shown inFIG. 4A was manufactured likewise the example 1-1 except the abovearrangement. Further, a rear projection screen provided with thediffusion sheet described above was obtained likewise the example 1-1.

Example 1-3

A diffusion sheet as shown in FIG. 5 was manufactured as a diffusionsheet according to an example 1-3.

Specifically, non-isosceles trapezoidal columnar unit lens portions, ineach of which the angle θ3 between one side surface (total reflectionsurface) and a light incident surface was set to 80° and the angle θ4between the other side surface (total reflection surface) and the lightincident surface was set to 82°, were disposed in such a manner that thesurfaces, which correspond to the side segments having the angle θ3, ofadjacent unit lens portions were disposed adjacent to each other, andthe surfaces, which correspond to the side segments having the angle θ4,of adjacent unit lens portions were disposed adjacent to each other,thereby the diffusion sheet was formed in the shape shown in Table 1.The diffusion sheet as shown in FIG. 5 was manufactured likewise theexample 1-1 except the above arrangement. Further, a rear projectionscreen provided with the diffusion sheet described above was obtainedlikewise the example 1-1.

Example 1-4

A diffusion sheet as shown in FIG. 6 was manufactured as a diffusionsheet according to an example 1-4.

Specifically, each of the side surfaces (total reflection surfaces) ofeach of isosceles trapezoidal columnar unit lens portions was formed ina broken-line-shape having a plurality of flat surfaces with a differentangle. In each entire side surface, the angle θ5 between a side surface(total reflection surface) on the side of a light incident surface andthe light incident surface was set to 80°, and the angle θ6 between theother side surface (total reflection surface) on the side of a lightoutgoing surface and the light incident surface was set to 82°. The unitlens portions having the broken-line-shaped side surfaces on both thesides thereof were disposed such that the angles between the sidesurfaces (total reflection surfaces) and the light incident surface ofadjacent unit lens portions had the same angle thereby the diffusionsheet was formed in the shape shown in Table 1. The diffusion sheet asshown in FIG. 6 was manufactured likewise the example 1-1 except theabove arrangement. Further, a rear projection screen provided with thediffusion sheet described above was obtained likewise the example 1-1.

Comparative Example 1-1

A diffusion sheet as shown in FIG. 18A was manufactured as a comparativeexample 1-1.

Specifically, the diffusion sheet was formed in the shape shown in Table1 as a whole by disposing isosceles trapezoidal columnar unit lensportions each having an angle of 78° between a light incident side andeach side surface (total reflection surface). The diffusion sheet asshown in FIG. 18A was manufactured likewise the example 1-1 except theabove arrangement. Further, a rear projection screen provided with thediffusion sheet described above was obtained likewise the example 1-1.

TABLE 1 Length of bottom Lens segment of light height h absorbingportion Pitch p (μm) (μm) W(μm) w/p % h/p % Angle Example 1-1 70 140 3956 200 82° Example 70 140 44 63 200 80° 82° 1-2 (θ1) (θ2) Example 70 14044 63 200 80° 82° 1-3 (average) (θ3) (θ4) Example 70 140 44 63 200 80°82° 1-4 (θ5) (θ6) Comparative 70 90 38 54 129 78° Example 1-1(Result of Evaluation)

Rear projection screens according to the examples 1-1 to 1-4 and thecomparative example 1-1 were provided with rear projection typetelevisions, and images displayed on the screens were evaluated. In eachof the examples 1-1 to 1-4, an image having good bright uniformity wasviewed at any of viewing angles. In contrast, in the comparativeexample, an image having bad bright uniformity was viewed even if it wasviewed from the front of it, and, further, a viewed image had irregularbrightness which was emphasized depending on a viewing angle.

Next, specific examples and comparative examples of the fourthembodiment described above will be explained.

Example 2-1

A diffusion sheet as shown in FIGS. 12 and 13 was manufactured as adiffusion sheet according to an example 2-1.

Specifically, first, a roll-shaped metal mold was prepared bysequentially cutting a metal mold material to form recesses for unitlens portions so that a diffusion sheet, in which a plurality of unitlens portions were continuously disposed, was molded by the metal mold.The plurality of unit lens portions were molded by the metal mold suchthat the horizontal section of each of the unit lens portions was formedin an isosceles trapezoidal shape, the width (pitch) of the lightincident surface of the unit lens portions was set to 70 μm, thedistance (lens height) between the light incident surface and the lightoutgoing surface of the unit lens portions was set to 150 μm, the ratioof the difference between the width of the light incident surface of theunit lens portion and the width of the light outgoing surface thereof tothe width of the light incident surface of the unit lens portion was setto 60%, and the average angle θ between the light incident surface andthe total reflection surface was set to 82°.

When the roll-shaped metal mold was formed, first, a mold material wascut and trapezoidal columnar recesses for unit lens portions werealternately formed, and then the remaining spaces of the mold materialwere cut, and trapezoidal columnar recesses for unit lens portions wereformed likewise. The roll-shaped metal mold was manufactured such thatthe projections between the recesses for adjacent unit lens portionstilted in the sequence of “left, right”, “left, right”, “left, right”, .. . .

A UV resin was buried in the roll-shaped metal mold prepared asdescribed above, and the diffusion sheet was manufactured using a PETfilm substrate having a thickness of 50 μm, wherein the UV resin had arefractive index n1 of 1.55 after it was set.

Thereafter, light absorbing portions were formed in the V-shaped groovesbetween the unit lens portions. The light absorbing portions were formedusing a light absorption agent composed of black beads having an averageparticle size of 3 μm and dispersed in an acrylic paint having arefractive index n2 of 1.49.

The diffusion sheet as shown in FIGS. 12 and 13 was manufactured by theprocedure described above. A support plate having a thickness of 2 mmand composed of an MS resin containing an dispersion agent and anultraviolet ray absorbent was bonded onto the light outgoing side of thethus manufactured diffusion sheet, and a rear projection screen wasobtained by combining the diffusion sheet with a conventionally knownFresnel lens sheet.

Comparative Example 2-1

A roll-shaped metal mold for a diffusion sheet was manufactured by thesame procedure as that of the example 2-1 except that the recesses forunit lens portions were formed by sequentially cutting a mold materialfrom an end thereof. Since the roll-shaped metal mold was manufacturedas described above, all the projections between the recesses foradjacent unit lens portions tilted in the same direction as shown inFIG. 19A. A diffusion sheet as shown in FIG. 19B was manufacturedlikewise the example 2-1 by molding it with the metal mold manufacturedas described above. Further, a rear projection screen provided with thediffusion sheet described above was obtained likewise the example 2-1.

(Result of Evaluation)

Rear projection screens according to the example 2-1 and the comparativeexample 2-1 were provided with rear projection type televisions, andimages displayed on the screens were evaluated. In the example 2-1, whenseveral particular points on the screen were viewed from a right sideand a left side in a horizontal direction, if the angle (observingangle) between the viewing direction on the right side and a verticalline passing through a point being viewed was the same as the angle(observing angle) between the viewing direction on the left side and thevertical line, the point had the same brightness, and even if theviewing angle was changed, the brightness changed gently, and thus animage could be easily viewed on the screen. In contrast, in thecomparative example 2-1, even if the viewing angles were the same, thebrightness of an image viewed on a right side was different from that ofthe image viewed on a left side.

Further, the gains in a horizontal direction of the diffusion sheetsaccording to the example 2-1 and the comparative example 2-1 weremeasured. As a result, in the example 2-1, a gentle gain curve wasobtained which was uniform on the right and left sides and had a peak ata center. In contrast, in the comparative example 2-1, a gain curve wasnonuniform on the right and left sides.

1. A diffusion sheet that diffuses light incident thereon from a lightincident side and causes the light to outgo from a light outgoing side,comprising: a plurality of approximately trapezoidal columnar unit lensportions disposed such that long-axis directions thereof are in parallelwith each other, wherein all surfaces of the unit lens portions, whichcorrespond to long bottom segments of approximately trapezoidal sectionsof the unit lens portions vertical to the long-axis directions thereof,are disposed on a light-incident-side flat surface; and a plurality oflight absorbing portions interposed between adjacent unit lens portionsof the plurality of unit lens portions to absorb external light incidentfrom the light outgoing side, wherein the plurality of unit lensportions are arranged such that a part of the light incident on the unitlens portions from the light incident side is totally reflected onsurfaces of the unit lens portions corresponding to side segments of theapproximately trapezoidal sections vertical to the long-axis directionsof the unit lens portions, each side segment of the approximatelytrapezoidal section of each of the unit lens portions vertical to thelong-axis direction thereof is formed in a broken line shape projectinginward, and the approximately trapezoidal section of each of the unitlens portions vertical to the long-axis direction thereof has a firstangle between one side segment, and a light-incident-side long bottomsegment, and a second angle between the other side segment, and thelight-incident-side long bottom segment, the first angle being differentfrom the second angle.
 2. A diffusion sheet according to claim 1,wherein a distance between a long bottom segment and a short bottomsegment of an approximately trapezoidal section of each of the unit lensportions vertical to the long-axis direction thereof is 120% or more to400% or less of a length of the long bottom segment.
 3. A diffusionsheet according to claim 1, wherein a length of a light-outgoing-sidebottom segment of a section of each of the light absorbing portionsvertical to a long-axis direction thereof is 40% or more to 100% or lessof a length of the light-incident-side long bottom segment of thesection of each of the unit lens portions vertical to the long-axisdirection thereof.
 4. A diffusion sheet according to claim 1, wherein asection of each of the light absorbing portions vertical to a long-axisdirection thereof interposed between adjacent unit lens portions of theplurality of unit lens portions is formed in an approximately triangularshape, and a vertex of the section on the light incident side thereof iscomposed of a straight line segment having a width of at least 2 μm. 5.A diffusion sheet according to claim 1, wherein a section of each of thelight absorbing portions vertical to a long-axis direction thereofinterposed between adjacent unit lens portions of the plurality of unitlens portions is formed in an approximately triangular shape, and avertex of the section on the light incident side thereof is composed ofa curved line segment having a radius of curvature of at least 1 μm. 6.A diffusion sheet according to claim 1, further comprising a supportplate disposed on the light outgoing side of the unit lens portions andcontaining a diffusion agent.
 7. A diffusion sheet according to claim 6,wherein a light-outgoing-side surface of the support plate is formedflat.
 8. A diffusion sheet according to claim 6, wherein the supportplate has an ultraviolet ray absorbing action.
 9. A diffusion sheetaccording to claim 1, wherein the unit lens portions comprise aradiation setting resin.
 10. A rear projection screen comprising: adiffusion sheet according to claim 1; and a Fresnel lens sheet disposedon the light incident side of the diffusion sheet.